Method and apparatus for total energy fuel conversion systems

ABSTRACT

An independent and conserved source of fuel and/or power comprises a top stage rocket engine firing up to 5000 F. at very high pressures, delivering jet flows up to transonic velocities into a near adiabatic tunnel for mixing in general and/or for transforming reactants introduced to suit specific objectives. The related compression is supplied by an independent prime mover which compresses its exhaust and other recoverable fluids. Low grade flows, thereby upgraded in temperature and pressure, are adiabatically contained, are further upgraded in the tunnel to become part of the prescribed fuel for export at the tunnel ends; or fuel to be fired in a prime mover for electric or other power, or hydrogen for chemical use. Expansion turbines for this purpose are relieved of the load used to compress the excess air in standard gas turbines thus increasing export power. A portion of the expansion turbine&#39;s exhaust becomes part of recoverable fluids. When oxygen is used instead of air, the gases through turbines are nitrogen-free with more heat capacity reducing turbine inlet temperatures for the same power. When reactant transformation is specified, the larger water vapor content in the cycle enhances the water gas/shift autothermally for ammonia and/or power and alternatively for pyrolysis cracking for olefins and diolefins. Further, staging rocket engine reactors increases efficiency in boilers and steam turbines; and staging can produce sponge iron and/or iron carbide as well as expansion turbine power and fuel cells for peak and off-peak loads.

This application is a 371 of PCT/US97/23946 filed Dec. 23, 1997 which isa continuation in part of Ser. No. 08/771,875 filed Dec. 23, 1996 U.S.Pat. No. 5,938,975.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to conservatively transforming carbonaceousmatter into fuels and petrochemicals for power and other purposes.

2. Description of the Prior Art

There have been many attempts to improve the efficiency of powergeneration systems in order to reduce the fuel consumption/powergenerated ratio, and to reduce environmental pollution from combustionproducts. Some of those attempts include gas turbine blade cooling,combined cycle heat recovery, and the Humid Air Turbine (HAT) cycle. Forexample, U.S. Pat. No. 4,829,763 discloses an intercooled, regenerativecycle with a saturator that adds considerable moisture to the compressordischarge air so that the combustor inlet flow contains 20 to 40% watervapor. The water vapor adds to the turbine output while the intercoolingreduces the compressor work requirement which result in higher specificpower. The compressed air which is used for combustion of the fuel todrive the turbine is cooled then humidified prior to combustion in amultistage counter-current saturator with the aforementioned watervapor. Low level heat is rejected from the compressed air duringintercooling and prior to humidification. The HAT cycle is animprovement in thermal efficiency compared to the combined cycle, thesteam injected cycle, the intercooled regenerative cycle and otherhumidification based processes. The HAT cycle requires very high airpressures up to 30 atmospheres and higher turbine inlet temperatures upto 2800 F. to improve overall plant thermal efficiencies.

Another system is considered to be an extension to the HAT cycle, and iscalled the Integrated Gasification Humid Air Turbine (IGHAT) has beendescribed by Day and Rao as a method of coal gasification based powergeneration that could provide high efficiency and low emissions at leastcomparable to an integrated gasification combined cycle (IGCC) butwithout the penalty of high capital cost that is usually associated withIGCC systems. Much of the cost savings from IGHAT comes from the factthat the HAT cycle can use low level heat from gasification quench waterin an efficient way via the saturator, whereas in an IGCC one mustrecover as much heat as possible from the raw coal gas in the form ofhigh temperature and high pressure steam, using relatively expensivewaste heat boilers. Additional cost savings occur because the cycle doesnot require a steam turbine condenser. Further, the large amount ofwater vapor mixed with combustion air is expected to reduce NO_(x)emissions to very low levels, assuming suitable combustion can beachieved at reduced flame temperatures.

Harvey et al., describe a process for reducing combustionirreversibility through off-gas recycling. The process has no bottomingcycle which is similar to a gas turbine with intercooling, reheating anda regenerator. The regenerator functions as a reformer wherein the fuelis cracked and partly oxidized by heat from the recycled turbineoff-gases. The off-gases contain oxygen and thus are used as oxygencarriers. Before each turbine stage, air is injected into the gas streamcontaining reformed fuel and recycled off-gases which are therebysequentially fired. The water vapor in the off-gases is partiallyliquefied in the series of water-cooled condensers after each stage;intercooling is accomplished by injection of the water. Analysis byHarvey, et. al. shows reforming for fuel conversion, but the gainspresented were limited by pinch point temperature in the reformer.Harvey, et al. plan further study of the effect of their proposedarrangement on efficiency at turbine inlet temperatures below 2300 F.,which in the analysis is the approximate high limit without turbineblade cooling.

To control turbine inlet temperature within acceptable metallurgicallimits (now 2600-2800 F.) gas turbine designers have resorted to excesscombustion air, diluents such as steam as in HAT or simple steaminjection, water injection or compressor intercooling. Concurrentlymetallurgists are working to develop ceramic components or coatingswhich can tolerate ever higher temperatures. This invention achievesturbine inlet temperature control by turbine exhaust recycle withconsequential high system cycle efficiencies. Capital is reduced byrocket engine reactor compactness and elimination of combined cycleequipment and its related efficiency reducing system infrastructure. Indealing with the exhaust from steam turbines, this invention utilizesmuch of the latent heat in the exhaust with consequent reduction in thecooling water load otherwise required for condensing steam for boilerfeed water.

It is therefore an object of the present invention to provide a methodof generating power from fuel with improved efficiency over priormethods, employing conventional turbine inlet temperatures withoutdiluent injection or intercooling. Another object is to provideapparatus for generating power from fuel in a more flexible, efficientand less polluting manner than prior art methods, at reduced capitalcost.

This invention can also be used as a pyrolysis reaction system to carryout either moderate temperature conventional pyrolysis or hightemperature total pyrolysis. U.S. patents by Raniere, et al. U.S. Pat.No. 4,724,272 and Hertzberg, et. al. U.S. Pat. No. 5,300,216 teach thatheating and quench in transonic flow must be accomplished at preciseresidence times with respect to shock type and shock location. Bothhydrocarbon and steam are heated and passed through separate supersonicnozzles before pyrolysis. Hertzberg further teaches that, afterquenching, the cracked gases may be passed through a turbine for energyrecovery and further cooling.

With this invention combined fuel conversion transformations andpyrolysis are also possible. U.S. Pat. Nos. 4,136,015 and 4,134,824 byKamm, et. al. teach a process for thermal cracking of hydrocarbons andan integrated process for partial oxidation and thermal cracking ofcrude oil feed stocks. Hydrogen available from heavy oil partialoxidation promotes yield selectivity. Moderate time-temperature crackingconditions are selected which result in substantial liquid product andtar yields which must be handled with difficulty within their processand in downstream processes.

It is therefore an object of this invention to provide a method ofpyrolyzing and hydropyrolyzing carbonaceous matter either alone or incombination with fuel conversion transformations at moderate or hightemperatures and pressures, achieving near total feed stock conversion,in a near total energy conservation arrangement. Another object of thisinvention to provide apparatus for pyrolyzing and hydropyrolyzingcarbonaceous matter either alone or in combination with fuel conversiontransformations at moderate or high temperatures and pressures,achieving near total feed stock conversion, in a near total energyconservation arrangement.

SUMMARY OF THE INVENTION

These objects, and others which will become apparent from the followingdisclosure, are achieved by the present invention which comprises in oneaspect a process of producing power comprising:

providing a turbine adapted to generate shaft work, said turbine havinga combustor; and a rocket engine having a nozzle and a compressor means;

feeding fuel and oxidant to the rocket engine and the rocket enginecompressor means;

feeding carbonaceous matter and water and/or steam to the rocket enginenozzle;

processing the output of the rocket engine nozzle into fuel for theturbine;

introducing said fuel and oxidant for the turbine to the turbinecombustor to produce carbon dioxide and water combustion products;

passing said combustion products through the turbine;

recycling a substantial portion of the hot exhaust from the turbine tothe rocket engine compressor means;

further recycling the hot exhaust from the rocket engine compressormeans to the rocket engine nozzle; optionally into one or more secondaryport downstream from said nozzle; and optionally as a compressed flowfor other uses,

controlling the inlet temperature to the turbine.

In another aspect, the invention comprises apparatus for generatingpower from fuel comprising:

a turbine having a combustor;

a rocket engine having a nozzle and a compressor means;

means for adding carbonaceous matter and water and/or steam to therocket engine nozzle;

means for feeding fuel and oxidant to the rocket engine and to therocket engine compressor means;

means for processing the output of the rocket engine nozzle into fuelfor the turbine combustor;

means for introducing said fuel and oxidant for the turbine to theturbine combustor to produce carbon dioxide and water combustionproducts;

means for recycling a substantial portion of the hot exhaust from theturbine to the rocket engine compressor means;

means for further recycling the hot exhaust from the rocket enginecompressor means to the rocket engine nozzle; optionally into one ormore secondary ports downstream from said nozzle; and optionally as acompressed flow for other uses; and

controlling the inlet temperature to the turbine;

Another aspect of the invention is an alternative process of producingpower comprising:

providing a steam turbine adapted to generate shaft work; and a rocketengine having a nozzle and a rocket engine compressor means;

feeding fuel and oxidant to the rocket engine;

feeding carbonaceous matter and water and/or steam to the rocket enginenozzle;

processing the output of the rocket engine nozzle into fuel for a boilerand fuel for a second rocket engine;

boiling water in said boiler to produce water vapor;

using the resultant water vapor to power said steam turbine;

quenching the turbine outlet steam with water; recycling the cooledsteam and water mixture to the rocket engine nozzle; and

transforming the output of the second rocket engine into a fuel product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of a rocket engine power source comprised of arocket engine, a rocket engine compressor means, a conserved energyreactor and a distribution means.

FIG. 2 is a diagram of a rocket engine power source flowing to anexpansion turbine whose exhaust is recompressed by a prime mover so thatmost of the compressor discharge is effectively recycled to a conservedenergy reactor.

FIG. 3 is a diagram of a rocket engine power source flowing to anexpansion turbine which is part of an existing gas turbine withproductive use of its connected compressor.

FIG. 4 is a diagram depicting the rocket engine power source flowing tothree expansion turbines in series interspersed with separate combustorswith independent oxidant supplies from the rocket engine compressormeans.

FIG. 5 is a diagram depicting a rocket engine power source incombination with a fuel cell and a second conserved energy reactor andan expansion turbine to optimize the base load and/or peak load forpower delivery.

FIG. 6 is a diagram depicting a rocket engine power source integratedwith a boiler and using two stage fuel transformations.

FIG. 7 is a diagram depicting a rocket engine power source and a boilerwith a hot gas flow extension to further improve system efficiency.

FIG. 8 is a diagram depicting two rocket engine power sources in acombined process for pyrolysis and fuel transformation to produceethylene and synthesis gas.

FIG. 9 is a diagram depicting the partition and distribution of thepower turbine recompressed exhaust gases to optimize heat utilizationwithin the system.

FIG. 10 is a diagram depicting a near total energy conversionarrangement for producing ethylene and other chemicals.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENTS

The process of producing power comprises:

providing a turbine adapted to generate shaft work, said turbine havinga combustor; and a rocket engine having a nozzle and a compressor means;

feeding fuel and oxidant to the rocket engine;

feeding carbonaceous matter and water and/or steam to the rocket enginenozzle;

processing the output of the rocket engine into fuel for the turbinecombustor;

introducing said fuel for the turbine to the turbine combustor;

passing combustion products through a turbine; and

recycling a substantial part of the hot exhaust from the turbine to therocket engine compressor means:

further recycling of the exhaust from the rocket engine compressor meansto the rocket engine nozzle; optionally one or more secondary portsdownstream from said nozzle; and optionally a compressed flow for otheruses; and

controlling the inlet temperature to the turbine.

Suitable gas turbines adapted to generate shaft work include standardand advanced commonly available gas turbines manufactured by GE, ABB,Solar, Siemens and others.

Suitable gas turbine combustors include combustors provided with the gasturbines or those specially designed for high steam operation.

Suitable rocket engines include jet engines manufactured by GE, Pratt &Whitney, Rolls Royce and others; and burners made by T-Thermal, JohnZink and others; and jet and rocket engines made by manufacturers ofpropulsion systems for magnetohydrodynamic generators up to 5000 F.stagnation temperatures such as TRW.

Suitable nozzles for rocket engines include deLaval typecontracting/expanding nozzles.

Suitable fuels for the rocket engine include methane, natural gas andpetroleum distillates.

Suitable oxidants for the rocket engine reactor include air and oxygen.

Suitable processing the output of the rocket engine nozzle into fuel forthe turbine combustor includes one or more near-adiabatic tunnels andnozzles sized to generate one or more shock waves and produce jetpropulsions to boost flow energy.

Suitable temperatures for introducing fuel for the turbine to theturbine combustor so that turbine inlet temperature is controlled withinexisting materials limitations, i.e., up to 2800 F. for new gasturbines.

Suitable means for recycling hot exhaust from the turbine to the rocketengine compressor include gas turbines, turbochargers, diesel enginesand other internal combustion engines.

Preferably the output from said rocket engine nozzle and said recycledhot exhaust gas from said turbine are transformed in a near-adiabaticatmosphere into said fuel for said turbine. By near-adiabatic atmosphereis meant that heat content of fuel gas, oxidant, carbonaceous matter andwater being fed are preserved except for unavoidable radiation or otherlosses to the environment.

In certain embodiments, carbonaceous matter is introduced into saidoutput of said rocket engine reactor downstream of said nozzle atvelocities sufficient to transform said carbonaceous matter into saidfuel for said turbine. Suitable velocities for such transformationinclude sub-sonic and supersonic flow up to Mach 2 and higher tocomplete reactions and deliver flow at turbine inlet pressure.

The carbonaceous matter is preferably methane, but can alternatively benatural gas and its components, petroleum coke, residua or distillates,biomass, coal, char or other chemicals suitable for pyrolysis orcombustion. Preferably said fuel is also methane.

In some embodiments a portion of said hydrogen is diverted to one ormore downstream uses, for example fuel cells, iron oxide reductionreactors, or chemical processes such as petroleum distillatehydrodesulfurization, hydrogenation of unsaturated hydrocarbons, ammoniaand alcohol production, etc. In some embodiments, a portion of saidhydrogen or other fuel is recycled by suitable means to fire rocketengine and downstream jet propulsions.

When the transformation occurs in a group of transformation reactors itis preferred that the pressure in said output of said rocket enginecompression means conforms by suitable means with the pressure in eachtransformation reactor.

In certain embodiments a portion of said hot exhaust from said turbinecombustor is compressed in an intermediate compressor and recycleddirectly to a short circuit distribution means and delivered as heat andmass additions at least matching or boosting pressure, jet-like, atsuitable junctures augmenting said hot exhaust.

Generally, the output of said rocket engine nozzle exits from saidnozzle at transonic speeds. By transonic speeds is meant near sonic andsupersonic up to Mach 2 and higher, suitable to the process reactionsand maintenance of designed flow energy level.

When reaction severity or selectivity in the transformation reactor orseries of reactors needs to be increased or when more mild operationsconditions are desired, catalyst for said transformation is introducedinto said output of said rocket engine nozzle. Suitable catalystsinclude manganese oxide and zinc titanate.

The shaft work of the turbine can be for electrical generation only, orcan also include work to operate one or more compressors or pumps.

One or more turbines, one or more combustors, and one or more electricalgeneration means are possible.

In certain embodiments, supplemental or interstage oxidant is added tosaid turbine combustor(s). The oxidant can be introduced in said turbinecombustor(s) to effectively control turbine inlet temperature. Suitabletemperatures for turbine blades and components are about 1700 F. forolder gas turbines up to about 2800 F. for current state of the artdesigns. Turbine inlet temperature can be increased consistent withimprovements in materials technology for higher temperature and higherefficiency operations.

Generally one product of said transformation is hydrogen. Other productscan be carbon dioxide, carbon monoxide, and water vapor, for example.

Another embodiment of the invention is a process of producing powercomprising: providing a steam turbine adapted to generate shaft work;and a rocket engine having a nozzle and a compressor means;

feeding carbonaceous matter and steam to the rocket engine nozzles;

feeding fuel and oxidant to the rocket engine;

processing the output of the rocket engine nozzle into fuel for a boilerand fuel for a second rocket engine;

boiling water in said boiler to produce water vapor;

using the resultant water vapor to power said steam turbine;

quenching the turbine outlet steam with water; and recycling the cooledsteam and water mixture to the rocket engine nozzle; and

transforming the output of the second rocket engine into a fuel product.The fuel product generally comprises hydrogen.

In some embodiments clean water is introduced into said transformationreactor or group of transformation reactors, thereby reacting in saidreactor or reactors with said output of said rocket engine. Preferably,the clean water is introduced in an approximately equal or greaterweight ratio with the steam turbine exhaust.

Preferred embodiments of this aspect of the invention include providinga heat exchanger; a third rocket engine having a nozzle; a gas turbinehaving a combustor; feeding fuel and oxidant to said third rocketengine; directing the output of said third rocket engine nozzle intosaid heat exchanger so as to cool said output and to super-superheatsteam from said boiler; and transferring the resultant super-superheatedsteam to said steam turbine.

One suitable apparatus for generating power from fuel according to theinvention comprises: a gas turbine having a combustor; a rocket enginereactor having a nozzle and a compressor; means for feeding fuel andoxidant to the rocket engine;

means for processing the output of the rocket engine reactor into fuelfor the turbine combustor; means for introducing said fuel for theturbine to the turbine combustor;

means for recycling hot exhaust from the turbine to the rocket enginecompressor means;

means for further recycling the exhaust from the rocket enginecompressor means to the rocket engine nozzle; optionally the secondaryports downstream from said nozzle; and optionally as a compressed flowfor other uses; and for controlling the inlet temperature to the gasturbine.

The high pressure high temperature gas turbines being developed may,with cost effective revisions, may be retrofitted according to thisinvention to increase their thermal efficiencies. Perhaps the greatestretrofit gains will redound to the many heavy-duty, low efficiency,stationary gas turbines already installed and operating in a lowertemperature range. Apart from the heat recovery via conserved recyclerecompression, the implementation of the independently poweredcompressor can completely eliminate the work of compression from theoutput power expansion turbine, thereby increasing its output net workand mechanical efficiency. This same gain is accordingly obtained with anew installation.

This invention achieves turbine inlet temperature control by turbineexhaust recycle with consequential high system cycle efficiencies.Capital is reduced by rocket engine reactor compactness and eliminationof combined cycle equipment and its related efficiency reducing systeminfrastructure. Nitrogen oxides normally associated with hydrogenproduction by steam reforming are reduced due to high steam, low air ornitrogen free reaction conditions and increased thermal cycleefficiency.

As mentioned, the invention comprises recycling a substantial part ofthe exhaust gases from an expansion power turbine; augmenting them withfuel additions and the combustion products of said fuel additions forcompressing them; recompressing them in an independent heat conserving,staged jet compression process and returning them to the expansion powerturbine; reacting said gases in a topping compression stage with arocket engine-driven water-gas shift hydrocarbon transforming and/orwater gas shift reactor (hereinafter referred to as the conserved energyreactor), for added thermochemical conversion resulting in recyclablefuel and extra fuel for other purposes outside the expansion powercycle; and; modulating turbine inlet temperature by controlled recyclingof augmented turbine exhaust flows. The present invention extends theart by improving efficiency, reducing gasification capital andminimizing environmental pollution; and adds capabilities beyond thestate of the art by carrying out the shift and other transformingreactions in another conserved energy reactor.

Shift reaction converts carbon monoxide to carbon dioxide and additionalhydrogen. Sequential conserved energy reactor designs will furtherreduce capital and improve process plant and power generation economics.

Referring now to the drawings, FIG. 1 show carbonaceous matter 100 andwater 99 as feeds to the secondary ports of rocket engine nozzle 120. Arocket engine 102 is fueled through line 101, preferably methane. Theoxidant, preferably air, is delivered to rocket engine 102 at toppressure via line 103 from the oxidant source. Oxidant is optionallybranched on line 104 to gas turbine combustor 105. Combustor 105 is alsofired with fuel 106 to control the turbine inlet turbine inlettemperature in combination with water 107.

Hot exhaust gases from combustor 105 expand through gas turbine 108. Theexhaust from the turbine in line 109 can be directed as 110 into any oneor more of secondary ports to downstream nozzles via related lines 111,112 and 113; or a portion or all of it as 114 can be branched off tojoin and become recoverable heat fluids carried in line 115. As analternate to the flow in 114, the flow 116 into compressor 117 deliversthe flow as 118 at system pressure to accommodate heat and mass balancefor the cycle. A farther branch 119 can be directed to the secondaryport of nozzle 120. Transforming reactors 121, 122 and 123 respectivelyrepresent water-gas, shift, and extended residence time zones wheretransformation of rocket engine exhaust occurs. These zones can beprogrammed optionally as sequential transonic shock zones or simply astwo or more residence time zones. Down-stream thrusts can be programmedby after jet combustion by introducing oxidant through lines 124, 125and 126 to fire with unreacted carbonaceous matter.

Un-utilized lines among 111, 112, 113, 124, 125 and 126 can beprogrammed to introduce other reactive matter. The extent of the usesdepends on the reactivity of the compounds present. A clean reactant forconversion, methane for example, into an auxiliary port of nozzle 120may require no more than two reaction zones. A pre-cleaned coal orpetroleum coke could require an additional zone. Solid feed stocksadditionally require the separation of particulates from the flow whichwould take place in particle separator 127. Another use for separator127 can be to recover particles secondarily entrained for any one of thefollowing functions by discharging:

1. Catalyst Particles;

2. Getter Minerals for alkali metal capture in biomass processes;

3. Sulfur Capturing Seeds like manganese oxide or zinc titanate forcoal, coke and residual oils;

4. Iron Particles for Steam Iron Reactions to produce sponge iron,produce hydrogen for fuel cells and other uses, and to recycle-reduceiron oxides;

5. Other Metal Particles like tin and zinc for thermochemical reactions;and

6. Neutral Particles for heat transfer to lighter faster flowingparticles, gases and vapors.

Any one or more of the above can be introduced by entrainment in a fluidthat is chemically compatible to the process. Some processes may requireat least one more separator 127 which may be in a cascade seriesmanifolded so that the product gas flows totally into nozzle 128 whichcan serve as a back pressure for the following process uses natural gas,cleaned or pre-cleaned carbonaceous matter is converted for directcombustion for turbine expansion, or an integrated fuel cell/turbineprocess. One capability of the rocket engine driven reactor train is toproduce a fuel gas to be used directly in combustion, as in laterembodiments. Another capability of the rocket engine driven reactortrain is to force the reactions to completion towards the lowestreaction end temperature by programmed, metered and controlled reactantfeeds. This is useful when maximum hydrogen production is desired forsubsequent chemical use. Most conversion reactors in practice quench thereaction to preserve its final chemical composition. By contrast, whenappropriate this invention fires the product gas at the end of thereaction for the stoichiometrically prescribed reaction end temperaturewhich ends at station 129 of the conserved energy reactor distributionmeans.

On the other hand, when the reaction end temperature does not conform tostill lower temperatures required by downstream processing, then thereaction must be quenched. Conversely, a process such as pyrolysis canrequire quenching to interrupt a reaction sequence and freeze desiredintermediate chemical species. Examples would include cracking ofmethane to produce acetylene and ethylene; cracking of ethane to produceethylene; and cracking of propane, butane and petroleum distillates toco-produce hydrogen, ethylene, propylene, butylene, butadiene and otherdiolefins, and aromatic compounds.

When oxygen is the oxidant of choice and its source is available overthe fence at pressure for the process, the need for a separate oxygencompressor means is eliminated. Otherwise a compressor means can serveto boost the pressure of the oxygen.

Line 130 shown branching off oxidant source is to provide oxygen or airto any one or more of the secondary ports to nozzle stations 120, 131,132 and 128 for increasing the thrust in the flow by after-jetcombustion. An ignition source is provided when the flow on contact isbelow the auto-ignition or reaction temperature. Ignition lines are notshown but are similar to line 133. The function of after jet combustionis to boost entrainment, create shock, and/or make up for friction headloss to maintain pressure at station 129.

Compressor 134 is shown powered by combustor 105 and turbine 108.However compressor 134 can be powered by any prime mover, a dieselengine for example, providing preferably that its fuel composition ischemically compatible with flow in the conserved energy reactor;otherwise the exhaust must be exported for recovery uses.

Standard equilibrium plots are used as guidelines for starting andrunning the conversion process so as to avoid the formation of solidcarbon or coke.

This process has the capability for making extra products, for example,synthesis gases for ammonia or alcohols, pyrolysis cracked gases forethylene and petrochemicals can be produced.

Typical Baseline Reactions for the Conserved Energy Reactor

The following are the main equations which relate selectively to anyembodiment incorporating the conserved energy reactor described withrespect to FIG. 1. The basic equations are as follows:

FIG. 1 also shows how additional fuel can be produced in addition toincreasing the efficiency of the power cycle. It shows the reactordischarging 3H₂+N₂ as synthesis gases for the ammonia process andadditional fuel as H₂+0.333N₂ which can be used for more steam ortowards fueling the rocket engine for export within the plant.

The following two equations illustrate the basic autothermal reactionstaking place in the reactor to produce these gases

The sum of the reactions (4) and (5) yield the following:

This is another special feature of this process i.e. the provision formaking extra products. The synthesis gases for ammonia can also beproduced in later embodiments employing gas turbines. The water gasshift equations (1) through (4) may be applied to all the embodiments ofthis invention depending on the carbonaceous matter to be converted.Methane or natural gas relate to equations (3) and (4) whereas coal,petroleum coke and biomass and residual oils can be processed via thewater gas shift equations (1) through (2). The water gas reaction yieldsH₂+CO generally from the first reactor and shown as lines 141 and 142depending on the ultimate use as process fuel gas or synthesis gas. Thesignificance of equilibrium in this invention is explained with respectto Equation 4 for example which produces four moles of hydrogen and onemole of carbon dioxide. For practical purposes a nearly straight linerelationship holds in the positive log₁₀ K scale from five to zerocorresponding to temperatures respectively from 1600 K to 880 K (Wagman,et. al.), or 2400 F. to 1100 F. approximately. Higher temperatures ofcourse also favor equilibrium. (Equilibrium constants by Wagman, et.al.)

In order to understand the particular significance of equilibrium withthis invention is to conceptualize a very high temperature jet, say 4000F., rich in steam progressively completing equilibrium particle byparticle of interacting carbonaceous matter as they travel down theprogressively decreasing log₁₀K function and corresponding temperaturesdown to 1100 F. and lower because it is possible with pressure to do soto a minor extent in the negative log₁₀K range. Driving to lowtemperature is beneficial if the fuel gas must be desulfirized. It alsois sometimes useful in this case to separate the carbon dioxide from thehydrogen as shown with lines 143 and 144. A further advantage whendriving a stoichiometrically specified reaction to completion at a lowtemperature is that less carbonaceous matter or fuel and less oxygen isrequired for the endothermic heat which results in less carbon dioxidein the off-gases.

On the other hand, if a pre-cleaned coal is the reactant, it can beuseful to drive the reaction to a higher end temperature for use inturbine combustor 129, whereby the reaction is set by firing throughline 133. However, a pre-cleaned coal generated fuel gas must have itsfly ash removed in separator 127 through line 145 Before being fired incombustor 129.

Flexibility for Pyrolysis

This invention can also be used as a pyrolysis reaction system as shownin FIG. 1 to carry out either moderate temperature conventionalpyrolysis or high temperature total pyrolysis. At moderate temperaturesethane, propane, butane and petroleum distillates may be cracked toproduce ethylene and acetylene and other olefins and diolefins such aspropylene, butylene, butadiene and aromatic hydrocarbon liquids. At hightemperatures, methane may be cracked to produce mainly hydrogen,ethylene, and acetylene. Cracking non-methane hydrocarbons at hightemperatures yields virtually total conversion to yield a productdistribution largely free of the normally produced cyclic compounds,aromatics and heavy aromatic oils and tars.

U.S. patents by Raniere, et al, U.S. Pat. No. 4,724,272 and Hertzberg,et al. U.S. Pat. No. 5,300,216 teach that heating and quench intransonic flow must be accomplished at precise residence times withrespect to shock type and shock location. Those skilled in the art knowthat rapid quench to a temperature about 1100-1300 F. is important topreserve yields of desired products and minimize coke formation.

The rocket engine 102 and nozzle section 120 of this invention coupledto reactors 121, 122 and 123 previously described represent a facilityhaving flexible reactor length, capability for creating different shockcharacteristics along the reaction path and for quenching through ports111, 112, 125 and 126 at different reaction time-temperature crackingseverities. Many degrees of freedom are available since any one or moreof said locations and including nozzle section 120 ahead of the selectedquench locations can optionally be used for transonic mass inputs andheat additions to the main flow. Quenching can be total or partial anddirect or indirect or a combination. Direct quench media may be water,steam, hydrocarbons and inert gases. Indirect quench is accomplished ina heat exchanger (not shown) at or near location 127 instead of theseparator shown. The quenched cracked products are discharged throughnozzle section 28 and distributed via line 146 to be further processedby suitable means.

Flexibility for Combined Production of Synthesis Gas and CrackedProducts

U.S. Pat. Nos. 4,136,015 and 4,134,824 by Kamm, et. al. teach a processfor thermal cracking of hydrocarbons and an integrated process forpartial oxidation and thermal cracking of crude oil feed stocks.Moderate time-temperature cracking conditions are selected which resultin substantial liquid product and tar yields which must be handled withdifficulty within their process and in downstream processes.

With this invention, combined fuel conversion transformations andpyrolysis are also possible. High temperature operation is preferred sothat complete breakdown and conversion of normally liquid or solidcracked hydrocarbon products is achieved. In combined mode synthesisgasses are first produced in one or more conserved energy reactors aspreviously described. Then, in a downstream conserved energy reactor,pyrolysis reactants are introduced to the high steam and high hydrogensynthesis gases flowing from the first conserved energy reactor andtotal pyrolysis is carried out as previously described. The presence ofhydrogen in relatively large quantities during pyrolysis adds to yieldselectivity towards desired products. The presence of steam inrelatively large quantities during pyrolysis reduces tendency for sootor coke formation.

To further enhance reactivity, further accelerate heating rates andfurther improve selectivity towards desired cracked productssupplemental oxidant may be added through available secondary nozzleports. In combined fuel transformation—pyrolysis mode direct waterquenching is preferred since the steam thus produced in situ is usefulin generating turbine power. Cracked products are passed through aturbine for further cooling by isentropic extraction of work and flow toother conventional separation processes. Either high temperature ormoderate temperature pyrolysis can be practiced depending upon feedstock, desired end products and economic factors. Direct or indirect orcombination reaction quenching can be practiced depending upon feedstock, desired end products and economic factors.

FIG. 8 is a diagram of a pyrolysis and fuel transformation process forethylene and synthesis gases. The process to be described isrepresentative in general of producing other hydrocarbons. Methane isfed through compressor 134 and is distributed to suit a high pressure inline 800 into combustor 102, line 801, nozzle section 120 and line 802as an option for after jet combustion. A fraction of the methane isfired with oxygen is combustor 102 for the endothermic requirement ofthe ensuing transformation reaction in the form of

CH₄+H₂OCO+3H₂ΔH=+49.3 kcal  Equation (1)

The remaining methane in combustor 102 serves to augment the mass of thejet. The synthesis gases produced in the conserved energy reactor isdistributed to suit three different purposes:

1. A fraction is recycled to fuel combustor 105 of the rocket enginecompressor means. The resulting exhaust from turbine 108 is recompressedby compressor 117 and is distributed along the reactor as shown;

2. A fraction is synthesis gas product; and

3. The remaining fraction is fed under pressure to a second stage rocketengine combustor and fired with oxygen to form the pyrolysis jet in theform and range of

CO+2H₂O TO CO₂+3H₂O

to crack ethane for the production of ethylene as previously described.

As previously described, the combustor of the rocket engine can operateat stagnation temperatures up to 5000 F. and relatively unlimitedstagnation pressures. The conserved energy reactor flexibility for shocklocation and down stream supplemental shocks were also described. Asanother note, methane, carbonaceous matter such as coal and residual oilmay be processed which then produce syngas in the form and range of

CO+H₂ TO CO₂+2H₂

Finally, quenching to 1300-1000 F. is required with water, steam, ahydrocarbon or inert gas at the point of optimum cracking severity inorder to freeze the desired intermediate reaction products. Any fly ashis removed in the separator at location 127.

Many other transformation reactions according to the invention takeplace at near sonic and supersonic conditions with high relative slipvelocities between reactants which break into shock zones with ensuingsubsonic flows. Intense reactivity is obtainable thereby with primaryjet temperatures up to 5000 F. (practiced in magnetohydrodynamic flows)and unlimited high pressures for practical purposes.

Turning now to pressure, increased pressure is known to favor manychemical reactions. As noted earlier, low pressures are suitable forbiomass gasification. It is also well known that biomass is much easierto gasify than coal with reactions occurring at lower temperatures andnear atmospheric pressure. Coal is optimally processed at higherpressures.

This invention incorporates suitable alternatives for varying reactorpressure for conversion and at the same time conserves the rocket enginepower source energy for conversion by the recycle function.

The distribution of pressure is as previously described with respect toFIG. 1 whereby the flow of recoverable heat fluids from compressor 134is branched off to line 136 to supply combustor 105. The remaining flowis divided into a branch line 137 supplying rocket engine combustor 102and branch line 138 to supply any one or more auxiliary ports downstream of power nozzle jet 120.

Flows in 137 and 138 are not necessarily fixed. Increasing the flow in137 causes a corresponding decrease in 138. Being able to control thisinterchange allows more or less temperature in combustor 102 for wholeor partial oxidation which can have the opposite effect from oxidantflow through branch 138, and this can be offset with more or lesscarbonaceous feed and water through lines 100 and 99.

A similar branching interchange is effected from exhaust line 109 fromturbine 108. This was previously explained as a routine routing. Thisinterchange significance reported here relates to recovery of exhaustheat and mass. In relatively low pressure operations all or most of theflow through line 109 can continue through line 110 and be distributedselectively along and down stream into the reactor. For process reasonsor for a stronger entrainment effect the same flow can be redirectedthrough line 119 where the combustion jet has the most entrainingeffect, which effect can be further amplified by increasing thetemperature in combustor 102.

The need for directing the exhaust flow through line 116 to bemechanically compressed with the oxidant flow in line 139 throughcompressor 134 is less here because of the low pressure characteristicof the process. However, similar functions occur in later expansionturbine embodiments which operate as high as 30 atmospheres at station129. Station 129 then serves as the high pressure high temperaturecombustor of the turbine. In that event recoverable heat fluids line 115are replaced by a large portion of the exhaust which is recompressedalong with the flow in line 116. Then the recoverable heat fluids supplyto all combustors is from another source to be later described for therespective embodiments. In every case, however, power developed by therocket engine and its compressor means must maintain in steady staterecycle flow of consistent chemical composition in a near-adiabaticcycle while conserving a substantial portion of the exhaust energy formore efficiently powering an expansion turbine means which deliversmechanical power or electricity.

In this event to recover a substantial portion of the exhaust heat andmass, the flexibility afforded by the above described branchinginterchange options from line 109 will serve to optimize the recyclesystem to deliver a constant and consistent mass flow to combustor 129,here powering the expansion turbine means. Most of the heat returningthrough the system will convert carbonaceous matter to fuel gas for thecombustor at station 129. Any additional sensible heat in the flow tostation 129 is conserved to flow through the gas turbine 140. To preventbuildup in recycle, the necessary export carbon dioxide, nitrogen andminimal water vapor will serve to preheat fuel, recoverable heat fluidsand other plant uses. These will be further described in theirrespective embodiments.

The invention can comprise expansion turbines; turbines with parasiticshaft work, and multiple turbine arrangements.

Case 1—Rocket Engine Power Source for Single and Multi-Stage Turbines

In FIG. 2 combustor 129 for the expansion turbine means 200 deliveringpower to generator 201. Any mechanically transmitted power load can beused. The turbine means can be a single turbine, a straight multi-stageturbine, or a multi-stage turbine with interstage heating. Preferably,the source of temperature and pressure which developed in combustor 129is the rocket engine power source previously described with respect toFIG. 1. The rocket engine power source also includes the conservedenergy reactor or transformer. Its function is not only to transformcarbonaceous matter introduced through line 124 into a usable productfuel gas into combustor 129 but to convert all or most of the powerexpended in compressing and heating in the rocket engine compressormeans, rocket engine and conserved energy reactor together into productfuel gas (and its sensible heat) flowing into combustor 129.

The encompassing function of this embodiment is to recycle a substantialportion of the exhaust part from the last turbine of said expansionmeans, except what must be exported from the cycle (at least for directheat and mass transfer) to prevent build-up in the process. Accordingly,the exhaust 202 branches off at 203 and continues on as 204 after beingincreased in pressure through compressor 205, for interstage heating inturbine means 200. Compressor 205 to be powered by turbine 108 can beindependently speed controlled by a suitable means.

It is essential that the mass and chemistry of the greater or overallcycle remain at steady state; so export mass 206 must be replaced by anequivalent mass with a conforming aggregate chemistry for continuity.For example, if CH₄ is the fuel of choice, reaction in combustor 129 isorganized as follows:

CH₄+2Air+xrecycleCO₂+2H₂O+7.5N₂+xRecycle  Equation (1)

where Recycle=CO₂+2H₂O+7.5N₂ and where x is higher the lower the designturbine inlet temperature, whereby x (CO₂+2H₂O+7.5N₂) can substitute forany excess air firing in common practice. Equation (1) is rewritten asfollows when oxygen is the preferred oxidant:

CH₄+2Oxygen+xRecycleCO₂+2H₂O+xRecycle  Equation (2)

where Recycle=CO₂+2H₂O whereby x (CO₂+2H₂O) is the substitute for theexcess air. The x term can be any number or mixed number. The flowexported at 206 must equal CO₂+2H₂O but can be fractionally larger forcycle balance as long as its equivalent chemical aggregate reenters thecycle for mass flow continuity.

Returning now to compressor 134 whereby the fuels for rocket engine 102and combustor 105 are methane fractions of the design heat value,considered to be the sum of heats arriving at combustor 129 includingany after-jet combustion additions. Compressor 134 receives anddischarges flow 207 which is branched into 208, 209 and 210. Line 208goes into combustor 105 and its main function by proportion is to governthe inlet temperature of combustor flow 209 into turbine 108 oversuitable range for recycle balance whereby the fraction of flow 210becoming 211 is optional on balance from zero flow to a maximum equal tothat of 210. It follows then when 210 is something greater than zero onbalance, it is held on zero for start-up. The compatibility of therocket engine, or in combination with downstream after-jet combustionpropulsions depends on the difference between the top pressure incombustor 102 and the design pressure for combustor 129. Combustors 102and 129 make up more than just marginally the following head losses:

1. Rocket Engine Nozzle

2. Friction

3. Propulsion Entrainment

4. Rocket Engine Compressor Means Exhaust Distribution

In effect these losses convert to heat in situ between combustors 102and 129 and hereby convert to useful fuel endothermically with some risein sensible heat in the products flowing to combustor 129.

At least in the foreseeable future, advanced gas turbines are designedfor temperatures to 2800 F. with blade cooling and combustor pressure upto 30 atmospheres. This invention has no practical high limit for thestagnation pressure in combustor 102, even if advanced gas turbines areplanned for much higher pressures than 30 atmospheres, or higherpressure process hydrogen uses are available.

In view of these boundary conditions the stagnation pressure differencebetween combustors 102 and 129 must also be reconciled with theendothermic heat requirement for the transformation and the sensibleheat content or the product fuel gas and the aerothermochemicalpropulsion design. This heat utilization must primarily take intoaccount that portion of the exhaust heat from the turbine and the heatof compression that delivers it to the rocket engine—conserved energyreactor sequence. For example, in applications where there is a largedifference in pressure between combustors 102 and 129, it is moreexergetic for the rocket engine compressor means to deliver the exhaustgases to the entrainment train toward the lower end of the pressurecascade but still above design pressure at 129.

On the other hand, when the pressure at 129 is well below the highpressure that the state of the advanced art (i.e. 30 atmospheres) forgas turbines, like 20-25 atmospheres, then the preferred mode is tooperate the flow at 212 through compressor 213 at maximum (i.e. equal to210). This relates to zero flow at 211 and simplifies the cycle balancewith respect to consistent chemical aggregate in mass flow.

Besides considering how varying the foregoing flow effects the designpressure at combustor 129, the main criterion is ultimately choosing acycle balance that achieves the most net work output from the turbinemeans with the most recovery from recycling a related optimum of exhaustgases. This criterion requires iterating the design pressure to a valuelower than 30 atmospheres, as for applications at lower pressures forretrofitting existing gas turbines operating up to 25 atmospheres. Thiswill be covered further in the next embodiment.

Returning to the rocket engine compressor means, the fuel fraction, line316, is sized for compressing the selected mass flow through compressor134. Since the internal second law irreversible heats are adiabaticallyconserved, ideal isentropic relations can be used at least as a firstapproximation for determining the net work from turbine expansion. Toillustrate turbine inlet temperature control and the recycle functionsof this invention, the simpler mode whereby CH₄ is fired withouttransformation follows:

CH₄+2O₂+4.5[CO₂+2H₂O]→{CO₂+2H₂O+4.5[CO₂+2H₂O]}ΔH=−191.7 kcal at 2515 F.

Liberty is taken for simplicity and as a safe side analysis of theturbine work for the above, by using Keenan and Kaye Gas Tables for 200%Theoretical Air. This represents one pound mole of any gas at 2515 F.and 25 atmospheres expanded to one atmosphere and 943 F.:

25 atmospheres 2515 F h₁ = 23753 Btu/pound mole of products  1atmosphere  943 F h₂ = 10275 h₃ = 13478

h₃ represents the ideal expansion work of the turbine.

200% theoretical air relates to a combustion product average molecularweight of 28.9 whereas the average for 5.5 [CO₂+2H₂O] is 26.7. The safeside value for determining the Btu/pound of product is 28.9. The lowervalue for this follows:

 h₃=13478/28.9=466 Btu/pound of products

Total Products Heat=440 pounds×466 Btu/pound=205040 Btu

Turbine Work Efficiency=Products Heat/Heat Content of 1 mole ofCH₄=[205040/344160]×100=59.6%

or approximately 60% with respect to one mole of methane

The theoretical minimum for recovery requires the steady state fuelinput to be equal in heat to the work of expansion. This is 60% for thisexample and relates to 13478 Btu/pound mole of products expandingthrough the turbine means, simply referred hereafter as the turbine.

The objective is to develop a stagnation pressure in the jet combustorthat is well above the turbine inlet pressure, which is taken here as 25atmospheres. A further objective, preferably is to arrange for asubstantial part of the recycle flow to be compressed by jet propulsionin the near-adiabatic path hereinafter called the tunnel, from the jetcombustor to the turbine inlet.

This is to take advantage of the 5000 F. thermodynamic potential notfeasible with rotating compressors. The lesser efficiency in momentumtransfer is offset because the rise in sensible heat is contained forexpansion so long as the stagnation pressure driving the jet is adjustedupward, and it can be, to deliver the designed turbine inlettemperature.

The foregoing operation requires two parallel compressors instead ofcompressor 134 shown, whereby one compressor delivers a smaller part ofrecycle flow at a pressure well above the turbine inlet pressure intojet combustor 102 to augment the combustion products and therebyincrease the mass entraining force of the jet. The other compressordelivers the larger portion of the recycle flow into one or moresecondary ports of the tunnel at pressures somewhat less than theturbine inlet pressure to be entrained and boosted in pressure by thejet mass and further as necessary downstream by after-jet propulsion.

In a simpler mode, the flow from compressor 134 is divided so that thelesser flow is directed to the jet combustor and the larger flow at thesame pressure can be directed just down stream from the jet into one ormore secondary ports of nozzle section 121, or be further subdivided forflow into ports 111, 112 and 113 along the tunnel. In this mode, jetpower is increased as necessary by increasing the stagnation temperatureof the jet combustor.

Another alternative embodying some of either or both functions of theforegoing modes with the distinct difference that the tunnel entrypressure of the recycle flows be somewhat less than the turbine inletpressure and that the jet combustor be independently powered by fuel andoxygen at any suitable temperature and pressure within the design limitsof the rocket engine where its pressure is independently developed byone of the compressors in parallel (earlier described and not shown) andconsistently the pressure of the recycle flow would be independentlydeveloped by the other parallel compressor.

The foregoing modes illustrate the wide range of operations to beselectively determined and optimized by computer analysis and tunneldesign based on advanced gas dynamics for jet propulsion. The objectiveis to apportion the fuel required for the recompressor distribution withrespect to:

1. The intermediate compressor means

2. The rocket engine stagnation temperature and pressure

3. Tunnel jet propulsions all in consideration of the portion of exhaustto be recovered and recompressed within the cycle.

The following continues the previous example for the case whereby allthe recompressions to 25 atmospheres take place in the intermediatecompressor means and 50% of the exhaust is selected for recycle and heatrecovery.

1. Recycle 50% as 2.75 [CO₂ + 2H₂O] and split same into two flows of1.375 [CO₂ + 2H₂O] Related Mass (Pounds) CH₄ (moles) 2. Total exhaustmass 5.5 [CO₂ + 2H₂O] 440 1.0 3. ½ exhaust mass 2.75 [CO₂ + 2H₂O] 2200.5 4. ¼ exhaust mass 10375 [CO₂ + 2H₂O] 110 0.25 5. Flow (3) iscompressed isentropically 220 0.5 by compressor 134 6. Flow (5) isdivided equally 1.375 is delivered at 2515 F turbine inlet temperature110 0.25 7. The other half 1.375 is delivered to combustor 108 forturbine inlet temperature control, i.e. 1.375 [CO₂ + 2H₂O] 110 alongwith fuel product (5) 0.500 [CO₂ + 2H₂O] 80 8. Together equal 1.875[CO₂ + 2H₂O] 190 9. Exhaust (8) is recompressed by additional fuel 1900.43 flowing sequentially into combustor 108 for 190/440 = 0.43 10.However 0.43 [CO₂ + 2H₂O] is additionally 34.5 0.08 recompressed in-situas 34.5 pounds 11. Total mass and fuel used for said recompressions: (5)220 0.50 (9) 190 0.43 (10) 34.5 0.08 444.5 1.01 1.01 × 440 = 444.4

Note: Although the foregoing recompressions are shown to take place withno rocket engine recompression, the analysis nevertheless equates to thetotal fuel which is required no matter how the recompressions aredivided (for this example) between the rocket engine, the intermediaterecompression means and down stream jet propulsions.

Although oxygen power is preferred, air is not precluded. A parallelexample with respect to one mole of methane gives:

CH₄+2O₂+7.5N₂+[CO₂+2H₂O+7.5N₂]CO₂+2H₂O+7.5N₂+[CO₂+2H₂O+7.5N₂]

This represents a mass flow through the turbine of 580 pounds. Againusing work output, h₃=13478 Btu/pound mole/28.9=466 Btu/pound.

Total heat flow 580 pounds×466.4=270512 Btu

Turbine Work=(270517/344160)×100=78.6% with respect to one mole ofmethane.

The recovery procedure with air is similar to that described for oxygen.However if half the exhaust heat and related mass is conserved i.e.21.4%/2=10.7%, then the work output becomes 78.6+10.7=89% of the heatcontent of one mole of methane.

The reason the air mode in these comparisons is more efficient than theoxygen mode is because the mass flow is proportionately larger. The massflow in each case was computed on the basis of the same turbine inlettemperature of 2515 F. and 25 atmospheres whereby the heat capacity of440 pounds of the [CO₂+2H₂O] function is significantly greater than the[CO₂+2H₂O+7.5N₂] function. This points up another great advantage of theoxygen mode i.e. by increasing the mass flow of oxygen mode to that ofthe air mode the same work output of 78.6% would develop with the sameheat recovery for a total of approximately 89% but a commensuratelylower turbine inlet temperature for the same power and therefore morebeneficial in turbine design. The following can be further deduced fromthe foregoing analysis:

1. When a thermal efficiency somewhat less than 100% is shown for acontinuous mass flow (as 440 pounds in the example), then the increasedfuel and compression heat representing 100% must redound in an increasedturbine inlet temperature. So, if the designed turbine inlet temperatureis at the metallurgical limit, then the recycle and recompression mustbe recast to comply. Otherwise the increased temperature results in moreturbine output work at steady state loads.

2. On the other hand, as a corollary to step 1 by recycling more exhaustthan exemplified, the mass flow from recompression flow additions willincrease over the 440 pounds and disrupt the required continuity forsteady state recycle. In this case the surplus representing surplus heatcan be transformed into fuel and be bypassed to contribute to the fuelrequirement for any one or more for the rocket engine via theintermediate compression means, and jet propulsion operations.

3. When transformation of carbonaceous matter is introduced (which canbe methane) into step 1 or 2, the result is more fuel and/or more heatwhich must be taken into account.

4. Except for exhaust portion which is not recycled and its heat contentwhich can be independently used, the recycle part of the exhaust and allits recompression heat and fuel additions are adiabatically containedand must be taken into account in the heat and material balance forturbine flow continuity with surplus heat and mass bypassed as convertedfuel to replace a corresponding amount in the base analysis. The by-passis necessary to preserve said continuity of turbine flow.

The foregoing analysis demonstrates that methane or any clean fuel canbe processed according to this invention without transformation byrecycle of a substantial part of the turbine exhaust, its heat recoverybeing adjusted for turbine inlet temperature control and continuity.Further, this invention provides for heat and pressure for turbineexpansion or transforms said heat and pressure into fuel for saidexpansion by a staged engine operation from which practically no shaftoutput work is delivered, but which converts all shaft work in-situ intoheat and pressure for said expansion directly or indirectly bytransforming carbonaceous matter into fuel in a near-adiabatic controlvolume. In other words, this is a near total energy control volumewhereby all energy sources entering result in a flow with heat andpressure being delivered for turbine expansion or fuel for turbineexpansion.

This invention is not limited to how the recovery of export mass andheat is obtained. An extraordinary recovery can be made by shortcircuiting a fraction of the turbine exhaust by by-passing the mass flow203 through compressor 205, becoming hotter flow to 203. This flow isproportionately distributed so that the heat recovery between one ormore stages preferably, but not necessarily, equalizes the flow betweenstages of turbine means 200.

Further, selected mass flow 203 not only adds heat at selectedinterstage locations, but more significantly it admixes, boosts pressureselectively and augments parent flow 214, passing as distributed throughthe stages of turbine means 200. To maintain continuity, constant mass203 branches off augmented flow 202, so that 202 then becomes flow 204which sequentially becomes remnant exhaust flow 207 after flow 206 isbypassed for heat recovery indirectly within the cycle or exported forplant use. A particular advantage of the short circuiting cycle is toincrease the work output without disrupting the mass flow continuityessential in the main cycle.

Case 2—Rocket Engine Power Source for Turbines with Parasitic Shaft Work

FIG. 3 shows this embodiment whereby the rocket engine power source isapplied to existing gas turbines and the flow from the conserved energyreactor is directed for clean-up at low pressures. Case 1 was presented,for transformations wherein the carbonaceous matter flowing into nozzle120 via line 124 is either pre-cleaned or clean at the start. In thiscase, clean-up is presumed necessary and this requires that the flowfrom the conserved energy reactor is discharged at whatever pressure andtemperature is needed to accommodate any one of several commerciallyavailable processes.

Hot gas clean-ups operating at about 1000 F. are preferred, because thecleaned gas at this temperature can then flow to the gas turbine atleast retaining this level of heat. On the other hand, the advancedkinetic activity previously described for this invention can completetransformation reactions at very low temperatures without heatdegradation from quenching. A further advantage for example, is that thecarbon dioxide fraction in the fuel gas can be extracted at lowertemperatures and pressures for other uses.

In these cases the conversion efficiency employing the rocket enginepowered conserved energy reactor can be better than 90%. This reducesfuel cost compared with current practice. Further, when a low costresidual oil or petroleum coke can be substituted for natural gas, fuelcost can be reduced an additional 50 to 250% or more, depending onmarket prices.

It is also appropriate for this case to consider the benefits ofservicing a retrofit operation with a clean or pre-cleaned fuel. Thisbrings into play much of the process described in Case 1.

FIG. 3 illustrates a process wherein all or most of the load of standardcompressor 300 is relieved so that in effect standard gas turbine 200 istransformed into a free-power turbine whereby the former load of turbine200 now becomes additional power output at 201.

Accordingly, the compressor 300, only as a matter of convenience, can beused for low pressure oxidant flows into the conserved energy reactorthrough line 301.

Case 3—Multiple Turbine Arrangements

FIG. 4 shows a multiple turbine embodiment whereby recycle for turbineinlet temperature control is optimized. The use of oxygen is alsoeffective when applied to multi-stage turbines by this invention.Several process modes are described:

A. First consider partial oxidation of methane by thermochemicaltransformation for direct interchange with recycle turbine exhaustgases. Some methane is fired in combustor 102 through line 401; theremainder is fired through line 124. The recycled exhaust gases arecompressed at 134 and first proportioned so that compatible flow 208 issized for the turbine inlet temperature of turbine 108. Accordingly,compatible exhaust 210 is largely compressed in 215 and delivered athigh pressure along the conserved energy reactor. The remaining lesserflows 402 and 403 can be optionally applied or turned off. The remaininglarge part of compressor discharge 404 is then divided to suit thetemperature and pressure interaction between combustor 102 and jetentrainment nozzle 120. The reaction zones can be applied as needed.Separator 405 is omitted. Nozzle 406 provides the back pressure for theflow on to top combustor 407. The partially oxidized gas continues onthrough combustors 408 and 409 to exhaust from bottom turbine 410 incomplete combustion to exhaust in line 202. Oxygen is supplied throughline 411 and controlled for flow content and pressure (not shown) intolines 412, 413 and 414. The control is for maintaining preferably equaltemperatures at each interstage to match the temperature in combustor407.

B. Methane can also be fired with a shortage of oxygen resulting in gasflow that is partially oxidized and be treated as explained in A above.

C. The thermochemical activity between methane and steam can varydepending on temperature and pressure. Either of the following reactionscan be obtained over a wide temperature range:

 CH₄+H₂O_((g))CO+3H₂  Equation (1)

CH₄+2H₂O_((g))CO₂+4H₂  Equation (2)

However the reactivity with coal/carbon can be applied to the process:

C+H₂O_((g))CO+H₂  Equation (3)

CO+H₂+H₂O_((g))CO₂+2H₂  Equation (4)

All the foregoing reactions are endothermic and operate within the heatand reactant content of the recycle part. In this way the cycle firstyields the endothermic heat and reactant steam for the transformationand then regains it when the product fuel gas is fired downstream. Thereaction equilibrium is well served by the abundant water vapor contentof the recycle part.

FIG. 5 shows an embodiment whereby the production of hydrogen ispreferably accomplished via steam—iron reactions. Either of thefollowing three ways are described for their different physical effectsin reaction equilibrium and kinetics with respect to how the ironproduct can be later stored and used:

A. Reduction of Fe₃O₄ to FeO for Hydrogen

B. Reduction of Fe₃O₄ to Fe (sponge iron) for Hydrogen

C. Carburization of Fe to Fe₃C (iron carbide)

FeO particles, derived from fairly sizable Fe₃O₄ particles (probablyfrom a pellet source), offer a unique characteristic whereby theparticles can lumber along forward from drag forces created by the highvelocity, reacting steam exerting slip velocities up to transonicspeeds. As a recycle process only the product hydrogen has to bedischarged at the end of the reaction zone. It does not matter if solidsrecycling are a mixture of Fe and FeO particles so long as suitablemeans are provided to preclude agglomeration in recycle. The orientationof the reactor by this invention can assume any angle with horizontalthat sustains the solid particles in flight.

An alternative mode relates to a very fine Fe particle in the 50 to 200micron range. At the lower end close to dust in size they must beconveyed by a neutral gas, nitrogen for example, in a sealed conduit topreclude spontaneous combustion. Because of this characteristic they canbe expected to develop very high reaction rates just by mixing withsteam. Further comments will ensue after examining the followingreactions for producing hydrogen from sponge iron, Fe:

according to Gahimer et al (IGT experiments 1976) Equation (4) has afavorable free energy change almost linearly from ΔG=−20 kcal at 125 C.to about −3 kcal at 925 C. The free energy changes for reactions “A”were computed from Thermochemical Properties of Inorganic Substances byI. Barin and O. Knacke. In view of Gahimer, the favorable free energychanges for the “A” reactions support both processes as achievable forhydrogen production by the rocket engine power source and the conservedenergy reactor. This is not to preclude running larger particle sizes in“B” reactions while still striving for an all-Fe or sponge ironproduction for other uses while producing hydrogen for fuel cells andgas turbines. Such a use is sponge iron for steel mills presented nextas “C.”

C. Carburization of Fe to Fe₃C (Iron Carbide)

The production of sponge iron is basically the direct reduction of ironoxides as described above and its use in steel is primarily to form ironcarbide (Fe₃C). With methane, as a major constituent of natural gas, thechemical environment is described by equation (1):

The following are the driving carburization reactions:

The foregoing illustrates the expansive applicability of the rocketengine power source of relatively unlimited high pressure range and a5000 F. ceiling for the rocket engine combustor as a facility for highproductivity in steel mills with a coordinated process which alsoproduces power. The combination for this is next described with respectto reactions “B” above and FIG. 5.

The sequence now is to generate for example, six moles of hydrogenindependently from the above equations by transforming methane in therocket engine power source. The hydrogen flow is divided equally intothree tracks:

Track 1 delivers two moles to fuel cell 500 (preferably solid oxide fuelcells) delivering power and high pressure steam into combustor 501 whichempowers turbine 502, as shown.

Track 2 delivers two moles of hydrogen directly to combustor 501

Track 3 delivers two moles of hydrogen to reduce 0.5 Fe₃O₄.

What follows next are the potential reactions in the first and secondstage operations. The first stage produces all the hydrogen and is apressure cascade. It empowers the second stage for the reduction ofFe₃O₄. The pressure developed in rocket engine 503 also delivers theoff-gases in track 3 from reactor 504 into the combustor 501 for maximumheat utilization. The reactions occurring in stage 1 are:

Reaction 5 takes place at top pressure inside combustor 503 so that thecombustion nozzle develops a jet as needed up to transonic velocitiesthereby activating reaction (6) which occurs when 1.5 moles of methaneare metered to react with the jet, accordingly producing in this examplesix moles of hydrogen equally distributed as above described to thethree tracks. The carbon dioxide is separated from the hydrogen bysuitable advanced means for retaining pressure and heat and directedfrom reactor 505 from said separation and on to empower the second stagesequence 506 and 504 for reducing the magnetite Fe₃O₄.

Accordingly, carbon dioxide and hydrogen flowing into jet pump 506extend the back pressure from stage 1 through a transonic nozzle tointeract with Fe₃O₄ particles being metered downstream of the carbondioxide and hydrogen jet according to the following reaction (7):

The foregoing reactions are approximately in heat balance so thatadditional heat may be added as necessary for process purposes. This issimply an example of the versatility of this invention to facilitate atwo stage reaction process. The jet pump 506 can readily be organizedfor combustion by introducing oxygen to fire a fraction of the hydrogen,and this can be the case when the carbon dioxide must be separated by aconventional solvent absorber-stripper or pressure swing adsorptionsystem.

The exhaust from turbine 502 comprises water vapor and carbon dioxide.The flows in the process would be iterated (not done for the purpose ofthis example) as described in previous embodiments whereby a substantialfraction in line 507 would continue on in line 508 into rocket enginecompressor means 509 and the difference in line 510 bypassed for otheruses.

Returning now to the production of iron carbide and using endothermicreaction (2) for example, sponge iron and methane react with heat toyield iron carbide [Fe₃C] and hydrogen. As an option, this is depictedin FIG. 5 as a third stage process whereby the methane is partiallyoxidized in the rocket engine combustor 511. Methane may be metered inexcess into the nozzle section of combustor 511 or metered down streaminto nozzle sections of sponge iron reactor 512. The jet from combustor511 accordingly supplies the endothermic heat of reaction to produce areiron carbide and hydrogen. In alternate modes the hydrogen produced fromreactor 512 can be recycled to the nozzle sections of combustor 506 andreactor 504 to reduce Fe₃O₄ and/or FeO to sponge iron thereby minimizingcarbon dioxide production.

In conclusion for this embodiment two further points are made. Firstly,a full power plant or peak load requires operating tracks 1 and 2together. In this way the turbine can be organized to handle the baseload on track 2 alone. Secondly, sponge iron can be commercially madeinto pellets or briquettes which can be conveniently ground into powderform. The reactivity of fine iron particles with steam can produce Fe₃O₄and pure hydrogen. This can be more suited for small fuel cells forresidences, for example. Polymer electrolyte membrane fuel cells arecommercially being developed for this purpose as well as somewhat largerunits for commercial buildings or mobile power sources. This class offuel cell minimizes high temperature components in dwellings andconfined spaces. This invention can produce the sponge iron for these orother fuel cell types with relatively small reactors for portability andsecurity as well as the aforementioned larger scale operations.

We next describe the rocket engine power source applied in two ways forboilers and steam turbines.

The Steam Turbine Power Cycle—General Considerations

Refer to FIGS. 6 and 7 which are later described in detail. Typicallysteam turbines in boilers are without connected compressors. As anexample, a steam turbine generator producing 50 MW would be powered by aboiler delivering approximately 346,000 pounds of steam per hour at 600psia and 1000 F. with an exhaust from the turbine at 250 F. and 30 psiaas dry saturated steam containing 1517 Btu per pound. Entropy isapproximately 1.7 Btu/pound R.

At constant entropy, the theoretical efficiency, neglecting pump work,is calculated as follows:

E={[1517−1164]/[1517−218]}×100=27.2%

The efficiency represented sets the point of departure between existingor new installations planned on the Rankine Cycle and this invention.The objective here is to recover most of the heat into the conservedenergy reactor for converting and developing all the fuel, retainingrecovered heat for firing the boiler. In completing the cycle, theefficiencies of the boiler and of the transmission of power between theturbine and generator will remain substantially unchanged. However, theinner cycle gain in entropy increasing the exhaust enthalpy will berecovered in the conserved energy reactor which will receive the exhauststeam directly as the major companion reactant with carbon andhydrocarbon compounds.

The latent heat in the turbine exhaust represents the largest part ofthe waste energy. At least 50% of it is recoverable by inter-mixing anadditional flow of water with the turbine exhaust steam on a one to onebasis. If all the latent heat is recoverable at this point in theprocess then the usual boiler efficiency of about 90% (100% forsimplicity) would also hold as the overall thermal efficiency for theadvanced operation. However the 27.2% efficiency shown above alsorepresents the overall thermal efficiency of a current operation. Thelost energy is 72.8%, which for practical purposes is the latent heatloss to cooling water. By recovering 50% this, as above described “E”becomes:

E=27.2+36.4=63.6%

The net work is nominally unchanged as 50 MW or 27.2% of the heat flowto the turbine. The fuel economy is greatly increased so that 36.4% lessfuel is needed to produce the same net work. Further, the cooling waterrequirement is cut in half and the additional water, 50% saturated afterintermixing is next used as the major water vapor reactant as 2H₂O intothe conserved energy reactor shown for example, with CH₄ by

For this analysis and in general two moles of steam can represent allthe steam that the boiler supplies as 100% and all for the turbine. Itis therefore consistent to recover as much heat from two moles ofturbine exhaust by the inter-mix flow transfer, above described, byrelating to two moles for continuity of mass whereby two moles ofexhaust continue on to the condenser and two additional moles with halfof the latent heat go into the reactor which supplies the fuel to theboiler. The added water must at least be as pure as the turbine exhaustso as not to contaminate the flow to the condenser.

The two moles of water vapor are thereby converted to fuel in the powersource. The fuel is next fired to provide 100% of the heat to the boilerby

CO₂+4H₂+2O₂→CO₂+4H₂OΔH=−221.2 kcal  Equation (2)

whereby the combustion products CO₂+4H₂O are stack gases (for cleanup asnecessary) to become the heat source in near adiabatic flow for a secondstage power source which can provide additional fuel at any pressure forany purpose for immediate use and part of which can be recycled to powerthe rocket engine and or rocket engine compressor means for either orboth first and second stage reactors.

It is preferable that in the foregoing staged operations the engines arefired with a clean fuel like methane and that at least in stage one thecarbonaceous matter is also methane or an equally clean and compatiblefuel. The following reaction(s) demonstrate the escalating benefit ofstage two:

CO₂+4H₂O+2CH₄3CO₂+8H₂ΔH=+79 kcal  Equation (3)

The effect of firing is shown by:

3CO₂+8H₂+4O₂→3CO₂+H₂ΔH=−462.4 kcal  Equation (4)

By comparing the combustion heat releases from Equations (2) and (4)with the endothermic requirements of Equations (1) and (3) it is fairlyobvious that there is abundant fuel available apart from exhaust heatrecovery both as latent and sensible heat from turbine exhaust and stackgases to further supply hydrogen recycle for the rocket engine andcompressor combustors. The carbon dioxide part may be retained orseparated and by-passed by suitable means.

A yield of eight moles of hydrogen is considered a maximum and the yieldmay be considerably reduced by lowering the flow of stack gases for thesecond stage reactor and directing the difference to low grade heatuses. On the other hand this mode, without or with less use of a secondstage power source, can apply the first stage in the use of othercarbonaceous less costly and/or less clean feeds which depend on in-situboiler or stack clean-up.

Case 5—Rocket Engine Power Source Integrated with Boiler

FIG. 6 is now described in compliance with the foregoing operations.FIG. 6 shows this embodiment in which a rocket engine power source isintegrated with a boiler utilizing the two stage fuel transformation.Steam exhaust from turbine 600 via line 601 flow into mixer 602 fordirect heat interchange with clean water, through line 603, which ismetered and pumped (not shown) to boost as necessary the flow throughthe mixer 602. The mixed flow 604 divides into flows 605 and 606 so thatflows 601 and 606 are mass-matched (control not shown) to preserveboiler feed water continuity through condenser 607 at a controlled lowpressure which also boosts the mixed flow 604 through the mixer 602. Asa consequence bypass flow 606 matches the mass content of clean waterinflow 603. Mixer steam flow 608 from boiler 609 joins the mixed flows601 and 603 to bring the clean water flow 603 at least up to the pointof vaporization. The minor steam quantity for this purpose becomes partof and increases bypass flow 606 over said mass-matched condition, whichnow as a partly saturated vapor is directed into a downstream port ofrocket engine nozzle section 120 (not shown). Increased flow 606accordingly becomes the major H₂₀ reactant with carbonaceous matter 610in the first stage power source. The fuel 611 can be any fuel but cleanfuels such as methane or natural gas are preferred for two stageoperation. The oxidant 612 is preferably oxygen for the first stage of atwo stage operation. The power source discharges fuel product 613through distribution means 614 which can be the fire box of boiler 609or simply deliver the fuel product to the boiler's fire box away fromsaid means.

The boiler delivers steam 615 which supplies minor bleed 608 (previouslydescribed) and which can be further divided into a steam flow 616 whichdirectly powers turbine 600 and discharges optional flow 617 which isdivided into flows 618 and 619 to suit make-up steam requirements. Theoptional flow 617 of course requires additional fuel supply 613 overwhat is necessary for turbine power.

There is a second more dominant option for flow 618 whereby thecompressor means is eliminated and combustion is precluded inside of jetcombustor 102 shown in FIG. 1 and flow 618 (up to full boiler pressure)empowers the jet so that the rocket engine is replaced by a powerfulsteam jet pump. However, combustion is not precluded downstream of thejet and can be applied for increasing the temperature and thrust of thedownstream flow. This feature, though not shown, can be applied to thesecond stage power source in this embodiment and likewise in the FIG. 7embodiment.

Continuing now with FIG. 6, steam rich stack gases 620 pre-cleaned asnecessary inside boiler 609 or outside (not shown), can be divided intoflows 621 and 622. Flow 621 is directed into a port of nozzle section120 (shown in FIG. 1) just down stream of the jet. Flows 621 and 622 areadjusted to suit the reactivity with flow 622 being directed accordinglyinto the conserved energy reactor. Other aspects of the second stagereactor are similar to those of stage one and generally of the powersource described in FIG. 1.

Case 6—Hot Flow Extensions of Boiler Embodiment

FIG. 7 shows this embodiment whereby a boiler arrangement is used with ahot flow extension to further improve system efficiency. The hot flowengine gasifier is powered by a standard industrial superchargeravailable over a wide flow range, for large industrial diesel engines.In this application, the turbine and compressor part are interspersedwith a custom built combustor designed to be fueled so that combustionproducts are chemically compatible and can flow adiabatically underpower, practically without heat loss, except for minimal radiation forincreasing the efficiency of the Boiler 609.

The turbocharger engine described is a simple cycle gas turbine and canbe started by any suitable means. The turbocharger—gas turbine ispreferred to an expensive conventional gas turbine (which is notprecluded) because the pressures anticipated are generally predicted tobe under four atmospheres.

Referring to FIG. 7 the hot flow unit compressor 700 receives air fromline 701 and delivers part to combustor 702 from line 703 at toppressure. The remaining air is delivered at the same pressure tocombustor 704. Combustors 702 and 704 are separately fueled by lines 705and 706 respectively by any compatible fuel, but preferably hydrogen inthe ration of 4 to 1 with carbon dioxide, which can be supplied by thesecond stage rocket engine power source. The products accordingly havehigh emissive potential for radiant heat transfer. The products fromcombustor 704 discharge through a sonic nozzle in conjunction withsecondary ports which comprise nozzle entrainment unit 707. The nozzleis integral with the combustor and the secondary entrainment ports whichseparately receive ambient air 708 and exhaust gases 709 from turbine710.

Extremely hot gases (2000 F. and higher) emanate as mixed flow comprisedof combustion products from 704, ambient air 708 and turbine exhaust 709coming together in channel by suitable means and continue as flow 711through heat exchanger 712 which further super-superheats the boilersteam 713 to 1600 F. and higher. The exit flow 714 can be deployed forfurther recovery by conventional heat transfer means to suit variousboiler needs.

The foregoing completes the hot flow cycle which for practical purposesis 100% heat utilization efficient except for minimal radiation andwhereby the turbocharger—gas turbine power, converting to heat in-situ,becoming intrinsically part of the total heat, comprises a total energyconversion adjunct to Boiler 609.

The hot flow velocities are planned to be very high so as to greatlyincrease the heat transfer rate in exchanger 712. This is a total energysystem whereby the turbocharger gas turbine's power heat equivalent istotally conserved, resulting in extremely high heat transfer ratesbecause the power for generating the necessarily very high velocities isconserved. As a consequence the ultimate benefit is a relatively smallerheat exchanger. Flow velocity, the essential factor, requires powerwhich rises as the cube of the velocity. Power here is not a cost factorbecause it is conserved, as already explained. Accordingly, by combiningthis intense heat transfer by convection with the previously describedhighly emissive radiation, heat fluxes up to 90,000 Btu per square footper hour and higher can be obtained.

The hot flow extensions to the conserved energy reactor described aboveeffectively create a total water and energy recovery system. Investmentcosts are minimized by the very high heat fluxes thereby greatlyreducing the surface area in exchanger 712. Water and its containedenergy is internally recycled; the turbocharger gas turbine's power heatequivalent is totally conserved; the energy required for high velocityheat transfer (which rises as the cube of the velocity) is not a factorhere because it is conserved, as already explained. The principleadvantage of increasing the steam temperature to about 1600 F. andhigher is that this substantially increases the turbine output whilestill retaining the conserved energy benefits of the two stage systemand the flexibility of being able to transform considerably less costlyfuels into more useful products. Of course it is also possible to addthe hot flow extension to the fuel cell arrangements described in FIG.5.

Referring back to and extending the 50 MW example, the followingdemonstrates the Hot Flow gain from just a 400 degree rise to 1400 F.,based on a nominal specific heat of 0.5 Btu/pound F:

E′=[(1717−1164)/(1717−218)]×100=36.9% for 68 MW

compared with 27.2% for 50 MW. The numbers speak for themselves. Everydollar for fuel heat energy spent in this way is reflected in equivalentelectrical energy without loss.

Turning now to FIG. 9 which is an extension of FIG. 4 and introducesthree options with respect to flow 212 shown in FIG. 2 as therecompressed exhaust from turbine 108. Both FIG. 2 and FIG. 9 show thisrecompressed exhaust delivered into the Conserved Energy Reactor andthis is also one of the options shown on FIG. 9 as flow 916. The othertwo options are:

1. flow 917 as an indirect heat transfer source for interstage heating,and

2. flow 918 as a direct heat transfer source for interstage heating.

Parent flow 212 may be apportioned to flow 916 and to flow 917 and 918.Controlled metering and throttling of these flow options (not shown) arepreferred. Also when two options are selected to apportion the exhaustflow from turbine 108, then each flow can be provided with a separateand additional compressor (not shown). This would allow one flow to be asignificantly different in pressure.

The main advantages of the flexibility provided by these options are:

1. They facilitate establishing and maintaining the continuity of themain cycle as to chemistry and mass flow;

2. While continuity is indigenous with a prescribed heat capacity, flow918 and particularly flow 917 provide additional heat capacity thattranslates to additional expansion power. The additional mass into thecycle by flow 918 is compensated for by programming the discharge atflow 206 to include an equivalent mass. Indirect heat flow is exhaustedfrom the cycle as flow 919 to be applied for further recovery; and,

3. Deploying all or much of the exhaust away from the Conserved EnergyReactor and the main recycle flow, the more parent exhaust mass and heatcan be delivered through line 207 for recovery within the main cycle,thereby minimizing external heat additions for completing the cycle.

Recovery flexibility is also enhanced by provision of separatecompressors 920 and 134. These are shown on the same shaft schematicallyfor simplicity. The main requirement is that they are independentlycontrolled and powered by the same turbine 108 or any prime mover solong as the compressor 213 is also powered by the same prime mover andits exhaust is recompressed by compressor 213.

Returning again to compressors 920 and 134, these are shown to receiveflows 915 and 209 respectively which are selectively apportioned fromexhaust flow part 207. One objective is for each compressor to becapable of delivering up to the highest pressure required by the cyclewhich is a relatively unlimited high pressure specified for rocketengine combustor 102. The second objective, accordingly, is to deliverthe least mass into combustor 102 from line 922, and the remainder at aselected lower pressure from 404 which may further be selectivelysub-divided for delivery into one or more secondary ports, via line 923,to the rocket engine nozzle section 120; or via line 924 into selectiveports of the Conserved Energy Reactor.

The main objective of the foregoing alternatives is to take fullthermodynamic advantage of the 5000 F. upper limit and top pressurecapability of the rocket engine combustor to support the prescribedoverall cycle requirement for the least pressure requirement fromcompressor 134 which is delivering the greater part of the mass into thecycle and thereby reduce the power otherwise required by turbine 108.This power may be further reduced by down stream jet propulsionpreviously described. The thrust force produced thereby increases theentrainment capability and the power of the flow for delivery into thepower output turbines.

As was earlier discussed in conjunction with the bench mark analysis forcycle optimization, the foregoing description with respect to FIG. 9further exemplifies the increased flexibility afforded by the twocompressors for selectively dividing that portion of the turbineexhaust, chosen for recovery within the cycle.

Returning again to the production of ethylene, further concepts relateto several functions for optionally arresting the chemical reactions forits production. This is complementary to the various ways previouslydiscussed for this invention for setting chemical reactions to aprescribed product resolution. These mainly, with the exception ofproducts involving products resulting in non-equilibrium mixtures suchas olefins, principally ethylene, were treated with respect toequilibrium related reactions in the production of synthetic fuels.

What follows further extends the treatment of ethylene. Transonic flowis extended over a significantly greater length in series sections as abetter control of the millisecond character of the pyrolysis residencetime and a further increase in selective length down stream in order tocontinue to accelerate the flow

1. Supersonically after shock and a brief interval of increased pressureto ensure flow through at least one sequent transonic nozzle;

2. Alternatively, the flow through the next or last de Laval nozzle canbe adequately fast for some reactions if only slightly subsonic.

3. This mode can also be appropriate when all flows and related nozzlesare designed to operate at slightly sub-sonic but increasing in velocitydown stream, so that acceleration after pyrolysis would be considerablygreater to enhance setting the reaction

4. Still another option is to program a shock after the pyrolysis zonewhich still continues to accelerate flow after a slight increase inpressure and a slight deceleration.

The main objective of the foregoing described accelerations particularlyafter pyrolysis is to set or “freeze” the planned reaction by causingthe temperature of the reaction to drop by converging the contour of thechannel or tube thereby changing the pressure head to kinetic energy.According to Raniere, a slight increase in pressure just after the lastshock zone, functions to offset the endothermic reaction by the relatedincrease in temperature. This is true providing an accelerating flow anda decrease in temperature follows.

Other variations with respect to the foregoing options can be practicedby those knowledgeable in fluid mechanics and/or gas dynamics within thecontext of this invention, so long as the objective for accelerations ispracticed as an in-situ cooling function, to set the pyrolysis reaction.In this way, the need for a water mist quench is either eliminated orminimized. If used, its preferred function thereafter is to expand theflow through a turbine in order to continue to drop the temperature.

The following comments are in support of the foregoing to employ shockwaves for pyrolysis. The advanced concepts of Hertzberg, Kammn, Raniereand others who teach various forms of shock activity may be compared orcontrasted with the art of Millisecond Furnaces which, though capitalintensive, have operated for years successfully in the marketplace andchallenge competitive efforts to devise a simpler, more compact, muchless capital intensive technology.

The other simple fact from a purely fluid mechanic standpoint is thatthe flow in the tubes of a Millisecond Furnace accomplishes thepyrolysis without shock waves. While furnaces differ with respect totube shapes between manifold entry and quench sections, consider an M.W. Kellogg furnace as described by Ennis, et al in their paper entitled“Olefin Manufacture via Millisecond Pyrolysis” (Chemtech MagazineNovember, 1975). The tubes are straight, approximately one inch insidediameter and approximately 36 feet long. For substantial ethyleneyields, the residence time is 0.03 to 0.1 second. With an outlettemperature range of 870-925 C. Accordingly, the average velocity in 36feet, ranges from 360 to 1200 feet per second.

The velocity of sound a=(g k R T/m)^(0.5) which as given for steam at925 C. is 2700 feet per second (Keenan and Kay Gas Tables). So with gRTconstant, Mach 1 for products would vary as k/m where k=Cp/Cv and m isthe molecular weight.

With this frame of reference the flow in this invention, in the shockwave mode, can by starting with Mach number of 3 or higher, cascade downto a lower Mach number selectively to suit the pyrolysis zone at the endthen allowing a slight deceleration of the flow before a relativelysteep acceleration to the turbine entrance. Accordingly, pyrolysis canbe considered to take place, selectively in the last shock zone as a“bottle” shock or compression shock conforming to the L/D ratiosrecommended by Ascher H. Shapiro in his text “The Dynamic andThermodynamics of Compressible Fluid Flow” under the heading of “NormalShocks in Ducts” pp. 135-137 and 1153-1156 (Ronald Press) 1954.

Supersonic zones can also be provided in series to promote mixing firstfor steam generation in-situ- and next to mix the feed with steamwhereby the feed is metered in at a substantially low velocity, but fastenough for tube cleanliness, whereby the steam-hydrogen mix is flowingat supersonic velocity. The boundary layer in ducts is impacted fromsuccessive shocks, in a “bottle shock” zone. When feed stocks aremetered in peripherally this action can be expected to assist itsdiffusion into the main stream and can minimize the growth of theboundary layer by entering with some kinetic energy into a low pressurezone, but still as a relatively low velocity compared with thesupersonic entraining stream. However, when feed is directed into a lowpressure zone, its velocity can be selectively increased in order forthe feed to penetrate deeper into the flow to further enhance mixing,particularly in advance of or into a shock zone. An alternate mode ofpyrolysis, as stated previously, can function at very high subsonicvelocities by this invention.

Further, it is to consensus that ascending heat rates increaseconversion for coal. See Von Rosenberg, U.S. Pat. No. 4,278,446. Withrespect to a temperature difference of 1500 K for a well dispersed coalparticle, he purports to attain a high heating rate of 106 K/sec.Reaction rates range from 0.6 to 2.4 milliseconds in a supersonicdiffuser approximately 2 meters long.

In his report to the U.S. Department of Energy (DE-AC 21-85 MC 22058,March, 1987), the team achieved coal conversion rates up to 70% in about50 milliseconds. The reactor length down stream of the DeLaval nozzlewas 80″ long to the quench station. Pressures up to about 4 ATM, andtemperatures up to 4000 C. were tried. The flows enter the supersonicdiffuser at Mach 2.27 and leave at Mach 2+.

It's of interest now to apply a heating rate of 105 K/sec to an ethanefed steam pyrolysis reactor of Hertzberg's U.S. Pat. No. 5,300,216. Thisis to estimate the reaction length portion devoted to achieve the 573 C.temperature rise given and shown on FIG. 2B of the patent. The peaktemperature 1000 C. is shown as a normal shock rise from 427 C. as themixed ethane and steam temperature. The pyrolysis temperature is givenan 863 C. The drop from 1000 C. to 863 C. is shown on the drawing as acusp down to the horizontal at 863 C. This is over a pressure and Machchange of 9 bars and Mach 0.44 to 10 bars and Mach 0.12 just beforequenching. At 1000 C. and 26.7 bars steam mixes with ethane at 381 C.for a final temperature after mixing, as above stated, of 427 C. TheMach number at this temperature is 2.8.

The above description is easily followed by seeing the patent drawings.The point is to show that the rise to 1000 C. could not take place overthe span of a shock wave. Accordingly, a prospective heat rate of 105K/sec is used to determine the time for the rise from 427 C. to 1000 C.and the related distance to the shock line shown in FIG. 2B. The shockline symbolizes a shock wave which Shapiro (p. 134) gives at 10-5 inchesor less in thickness for shocks just above Mach 1.

The thickness is also related to the mean free path between molecules.The ratio of the thickness to mean free path is 2 for shocks in the Mach2 range and higher. To bring the 105 C./sec in perspective, the time forthe rise is determined:

t=573 C./105 C. per sec=0.0006 sec or 0.06 ms, approximately

For an order of magnitude approximation, the mixture at 427 C. isconsidered steam at 1300 R. From Keenan & Kaye Table, the velocity ofsound for steam is given as 2100 fps

Mach 2.8×2100 fps=5880 or 6000 fps

Related reactor length is

6000 fps×0.0006 sec=3.6 feet

This length is in the same order of magnitude as the work of VonRosenberg for the Department of Energy. However, this rate pales withrespect to the rate that would be required for a 573 C. rise intemperature if it had to take place in a distance of 10-5 inches.

This is not to question the rise, but the space-time relationship inwhich it occurred. Presumably, the temperature started to rise in theso-called mixing zone of FIGS. 1 and 2B.

In this context, it is noteworthy to compare the work of Raniere, U.S.Pat. No. 4,724,272. He clearly illustrates pyrolysis in the multipleshock zone, as does Von Rosenberg. Raniere's FIG. 1b shows a steadilyrising temperature there, corresponding to a linear deceleration invelocity. Raniere maintains a supersonic velocity above Mach 2 throughmost of the reactor where multiple shock or “bottle shocks” start tooccur. The flow goes subsonic before entering a converging subsonicdiffuser. His reactor processed 1500 tons per day of methane yielding 43TPD of ethylene while recycling methane and hydrogen. He develops a Mach2 flow at about 3 atmospheres powering the jet and operates thepyrolysis at 500 to 2000 C.

These operating details are mentioned because they are widely differentthan Hertzberg's. They point up the plausibility of a process accordingto this invention, which provides a wide range of flexibility andcontrol with the further benefit for facilitating scale-up which doesnot preclude the use of shocks, but presents an alternate embodiment ofa reactor designed for accelerating high subsonic flows which can employshocks selectively for mixing and/or pyrolysis, but which, on the otherhand can operate by the further embodiment without shocks at all.

In keeping with the total energy aspect of this invention and here withrespect to the production of ethylene (but which also can be practicedin the production of synthesis gases) is the generation of steamin-situ, in the combustor of the rocket engine. When necessary,additional steam can be generated just down stream from the rocketengine nozzle where additional heat can be added as needed.

The preferred fuel for the rocket engine is hydrogen. So if more spaceis needed for steam generation, the heat for this can be provided fromfiring the related additional hydrogen either flowing (preferably) aspart of the jet or added secondarily just down stream of the jet. Thehydrogen is provided by an independent rocket engine power source as afirst stage operation to the foregoing ethylene cracker embodimentsdescribed. Other fuels can be used so long as the combustion productsare free of oxygen and are also chemically compatible with the pyrolysisfunction. A jet slightly rich in hydrogen is also compatible in somepyrolysis operations. Its richness is of course increased for after-jetcombustion when additional steam is required downstream of the jet.

Specification of the Invention—In the pyrolysis of olefins with respectto sonic and/or transonic flow FIG. 10 is a diagram of a near-totalenergy steam pyrolysis closed cycle for producing olefins in the rocketengine powered transonic mode.

The alternative mode whereby the flow is near-sonic and continuouslysub-sonic throughout is not configured.

Of course combinations of the two modes are still in the context of thisinvention as readily understood by those knowledgeable in the field ofgas dynamics, particularly when there is a transition from gas dynamicsin-situ to sub-sonic flow of the venturi type in fluid mechanics.

Turning now to FIG. 10:

1001 is a rocket engine combustor designed for temperatures up to 5000F. and relatively unlimited pressures. 1002 is a DeLaval nozzle designedin the range of Mach 0.8 to 5.

Steam is generated in 1001 in-situ by injecting water into the Rocketengine combustor. When additional steam from water is required in theprocess, this takes place in diffuser 1003 which, in this case, ispowered and served by DeLaval nozzle in the Mach 0.8 to 0.9+rangewhereby the combination of 1002 and 1003 comprise a venturi whereinadditional water is metered in for steam generation.

When additional steam is not required, the nozzles 1002 and 1003 aredesigned for super-sonic flow in the range of Mach 1+ to 5.

In either case, nozzle 1004 and diffuser 1005 are transonic fordelivering super-sonic flows into duct 1006, which is preferablyconstant in cross-section (although a slightly diverging duct ispermissible). In either case, the design and related process flow ispreferably programmed to emerge from 1006 in sub-sonic flow which can beincreased in pressure by a slight divergence in the extension (notshown) of duct 1006 before converging severely in 1007 intoclose-coupled expansion turbine 1008 which exports power P, which may beoptionally applied to turbo-charging or in the generation ofelectricity, AC or DC, to be used preferably within the process.

Accordingly, what is being described is a quasi-closed loop for neartotal energy conversion where the principle source of power (in keepingwith this invention and that of the many previous embodiments) is therocket engine power source 1001 as a pressure-temperature cascadewhereby the turbine 1008 converts part of said power into export power Pwhich can be returned to the cycle without specificity as practicallyapplied by one versed in conventional process engineering.

Continuing now in the loop, the flow passes into condenser 1009. Thecooling water (not numbered) indicated by arrows, is preferably deployedand further heated as the source of steam to be fed into a first stagerocket engine power source and conserved energy reactor which supplieshydrogen or hydrogen containing fuel gas into combustor 1001 throughline 1022 of the second stage rocket engine.

The oxygen requirement for firing combustor 1001 can come in on line atsystem pressure, or be compressed by the efficient power source ofprevious embodiments. For this mode the oxidant is represented on FIG.10 as oxygen. An alternative mode using air would require a similarcompressor means.

A further process can involve additional hydrogen 1015 down stream anddistributed to the pyrolysis reaction in zone 1 via 1003 with the feedstock and/or as 1016 into zone 2 via 1004 and/or zone 3 via 1005. Ineach case the flows are to be controlled and metered by suitable means,as with all flows in the process in order to govern the prescribedstoichiometry.

The alternative functions of duct 103 are: to produce more steam asneeded, to generate high subsonic flows or to produce high supersonicflows with respect to jet 1002. Each mode, each design and coordinatedflow specification are tailored to meet a programmed process. Thesefunctions have been previously described as an interrelated series ofducts 1002, 1003, 1004 1005, 1006 and 1007.

This series is further described as functions in zones 1 through 4,particularly with regard to the right and left hand end of duct section1003. Accordingly it converges to the right for any one of the followingfunctions for:

A. Accelerating high subsonic flows to and through its right hand nozzleextremity from an overall venturi action from jet 1002 on the left;

B. Building up an adequately high static head at duct 1003's largestintermediate cross section so as to produce a transonic jet at its rightend nozzle, thereby producing a high supersonic flow from zone 1 to zone2; and continuing in supersonic flow to selectively produce “bottle”shocks or a normal shock in zone 3.

C. Developing an adequately high Mach number (up to mach 5 or higher) asneeded at jet 1002, so that in producing a transition shock as the flowenters the right hand or converging contour of duct 1003 enough statichead is retained to selectively produce a high subsonic velocity or alower supersonic velocity at the right hand nozzle of zone 1.

Although the cascading Mach sequence just described effects adecelerating flow through zone 1, the cascade can be governed byselecting a stagnation pressure in the rocket engine combustor 1001 incoordination with jet 1002, so that the flow, as sated above, throughthe right hand end of zone 1 is either a high subsonic or an adequatesupersonic flow. Notwithstanding the deceleration, the ducts 1006 and1007 (relating to zones 3 and 4) are further correlated and are therebycontoured to accelerate the flow as earlier described. In this way theflows through zones 3 and 4 for cases A<B and C are similarlyaccelerated. Furthermore, for all cases the foregoing functions forflows through zone 1 will hold irrespective of steam generation therein.

A main objective of this invention is to accommodate a wide range offeed stocks and production resulting in a wide range of flows, as wellas to facilitate scale-up from prototypes. It is therefore by no meanslimited to 4 zones, provided the functions of zones 3 and 4 become 5 and6 for example. In this event zone 1 would repeat as zones 1 and 2 withzones 2 and 3 becoming 3 and 4.

On the other hand for some processes a shorter series can be applied.Accordingly, intermediate zone 2 can become the right hand of zone 1,thereby discarding the right hand end of zone 1, and so forth.

The condensed steam and product gas from condenser 1009 are separated in1010. The product gases, largely olefins, are exported for furtherprocessing and use. The warm water separated is pumped by 1011 to becomethe water 1013 for regenerating the pyrolysis steam in nozzle diffuser1002-1003 after by-passing excess water at station 1012. Return waterflow 1013 is shown divided into flow 1017 for high pressure injectioninto combustor 1001 and/or as high or low pressure flow just down streamof the jet. Water 1014 at low pressure from an outside source isintended to mainly for startup and as a trimming function for lateradjustments for steady state flow.

As an added function, steam 1014 is bled and by-passed through controlvalve D for minimizing or largely eliminating the boundary layerdeveloped by “bottle shocks” which develop boundary layers in constantarea ducts. This steam can be jetted in at the beginning of or throughthe boundary layer region, through perforations, slits or forced throughporous media.

Another embodiment employs steam 1021 as a trimming function andalternatively to effectively replace all or most of the in-situ steamgeneration. It does this while still retaining the quasi total energyobjective of this invention as well as the fluid and gas dynamicfunctions above described.

Steam feed 1021 can also be provided with dirty steam which is availablein some plants. Clean steam can be supplied by a separately heated steamgenerator or boiler which is integrated with the pyrolysis cycle.Accordingly, condensate 1013 instead of flowing for distribution intothe rocket engine complex as shown in FIG. 10, now is directed through apurification process before being returned to the boiler.

The advantage of the boiler embodiment is that it minimizes the quantityof hydrogen for the pyrolysis cycle. In the preferred embodiment, theboiler is provided with its own rocket engine power source whichdelivers fuel for the boiler as previously described for the otherboiler embodiments of this invention.

When the boiler is specified exclusively for the pyrolysis cycle, thepreferred fuel gas is delivered by its rocket engine power is hydrogenand carbon dioxide because it can be produced in excess, so that theexcess is bypassed to fire the complimentary rocket engine powering thepyrolysis train. This firing is programmed to adjust or increase thetemperature of steam from the boiler entering the same rocket enginecombustor at a common controlled pressure. The carbon dioxideaccordingly compliments and augments boiler steam as the pyrolysismedium. When air is the oxidant, the pyrolysis medium becomes steam,carbon dioxide and nitrogen.

This boiler can also be designed to produce an additional quantity ofsteam for powering a steam turbine, as a compliment to turbine 1008,thereby providing adjustment toward the total power for the process.Another advantage of the boiler embodiment is that it minimizes theoxygen or air requirement and accordingly the mechanical compressionrequired for powering the rocket engine for the pyrolysis train.

The pyrolysis train can also be a small process addition to a largesteam generating plant. Accordingly, all the previously describedfunctions and combinations are similarly applied.

Returning again to the non-boiler embodiment, the preferred fuel gas tobe provided for the rocket engine powering the pyrolysis train ishydrogen and carbon dioxide. The hydrogen is fired to produce steamin-situ from water. Accordingly, less steam and less hydrogen isrequired, because of the carbon dioxide compliment; and, of course,still less is required if the hydrogen is fired with air, because of thenitrogen compliment for the pyrolysis medium as described for the boilerembodiment.

The main source of power for the cycle is the cascading temperature andpressure developed in the rocket engine combustor. The controllingparameters for the cycle are the prescribed temperature and pressure todeveloped for the pyrolysis reaction wherever it is programmed to occur.To the extent that the pyrolysis pressure can be favorably increased forthe desired chemical reaction, it is preferable to build up pressure soas to increase the turbine export power toward approaching the pumpingpower required at 1011. In low pressure reactions, the balance of poweris approached by increasing the flow in line 1018 while controlling theflow in line 1017 toward zero. The balance is further improved whenenough power is generated for driving the compressor 1020 which deliversthe cracked gases through line 1014.

Not previously mentioned, some condensate can be recycled and applied asa quench medium just prior to converging duct 1007 to assist whennecessary as an additional way to reduce the temperature of the flowafter pyrolysis in order to set the olefin reaction. The increase inmass flow through the turbine serves to offset to some extent, the lossin power due to related decrease in turbine inlet temperature.

In summary, two principle embodiments have been presented with respectto a second or common final stage reactor train as shown in FIG. 10. Inthe first case, the first stage comprises a cascading rocket enginesource of fuel gas and power for the final stage, and steam is generatedin-situ. In the second case, the first stage comprises a boiler rocketengine complex whereby the boiler provides the steam and pressurelargely for the second stage; and the rocket power source provides thefuel for the boiler and a prescribed fuel gas excess for the secondstage.

Each two stage complex represents a quasi-total energy reactor cycle forequilibrium and no-equilibrium chemical processes whereby practicallyall of the mechanical compressive energy inside the loop converts firstto heat and then to chemical energy and sensible heat in the productchemicals.

Further, it can be readily deduced by those familiar with states of theart in fluid and gas dynamics, as well as the production of steam, thatfinally the rocket engine source of power and fuel described from theonset of this invention, including the boiler variations, can also beapplied for kinetic control in equilibrium reactions as described withrespect to FIG. 10 for pyrolysis reactions relating to the production ofolefins and diolefins.

In conclusion the disclosure of this invention involves dispensing powerin a cascade to one or more prime movers, expansion turbines for exampleso that the ultimate delivery is electricity or mechanical work. Withinthe cascade action, hydrocarbon fuels or other carbonaceous matter aresubjected to an aerothermochemical driving force, a relatively unlimitedstagnation pressure and combustion temperatures up to 5000 F. fordelivering jets of compatible formulation to bombard and/or entraincarbonaceous matter introduced downstream. The consequence is theproduction of a fuel gas that is more economical and morephysiochemically suitable for the prime mover. The exhaust from theprime mover is then suitable to a cycle whereby it is recompressed anddelivered at top pressure to the top of the cascade. The part of theexhaust that is bypassed for export can be used to preheat the oxidantand fuel entering the cycle for the recompression of the exhaust. Thefuel for recompression provides a substantial part of the top combustionpressure requirement. Similarly accounted fuel can also be applied forjet propulsion entrainment at one or more locations downstream of thetop jet; that is, between the top jet and the head of the turbine orother prime mover where the fuel gas is fired at the design temperatureand pressure.

The reactor can transform and provide reactant products for any purpose,with or without producing electricity. Further, waste heat can beapplied to an endothermic heat requirement for many reactions similar tothose described in this invention. Hydrogen and synthesis gases areprovided for ammonia, methanol and other petrochemicals. Ethylene,acetylene and other cracked pyrolysis products are provided fordownstream refining and petrochemical operations. Mixed reactions withsolids such as iron oxides and sponge iron for steel mills and fuelcells also produce exceptional results with this invention. Finally,temperature and pressure largely are depended upon to drive reactions tocompletion through one or more transonic zones. By metered andcontrolled stoichiometry, with reactions taking place in millisecondsand with the intense gas dynamic action described, kinetic control inprocess operations can be developed over relatively short time spans.Metered and staged stoichionetry in a kinetically controlled reactionenvironment results in autothermal quenching. If desired, conventionalquenching to freeze intermediate reaction species may be employed. Also,catalysts may additionally be employed to promote reaction at lesssevere operating conditions and achieve concurrent removal of sulfur andother pollutants.

Applying the power source described in this invention to a whole varietyof electric power, chemical and other process uses can fill a great needin industry and the world.

What is claimed is:
 1. Apparatus for generating power comprising: aprime mover; a rocket engine having a nozzle and a compressor means;means for feeding fuel and oxidant to the rocket engine and to therocket engine compressor means; means for feeding carbonaceous matterand water, steam, or a mixture of water and steam, to the rocket engine;and means for recycling hot exhaust from the prime mover to the rocketengine compressor means and means for passing the compressed output tothe rocket engine.
 2. A process whereby combustion powered energy isapplied to the compression of the products of said combustion and/or ofother combustions in an adiabatic continuum wherein said energy convertsto heat, pressure and flow energy which culminates at the end of saidcontinuum at a prescribed temperature, pressure and mass for fluidpower.
 3. The process according to claim 2 whereby a rocket engineseparately fired with fuel is organized in said continuum to receive asubstantial amount of said products from at least one of saidcombustions at top pressure, as an additional source of energy and massfor said fluid power.
 4. The process according to claim 3 for theproduction of iron carbide in at least two steps whereby methane ispartially oxidized in a last stage rocket engine combustion providing ajet with an excess methane fraction or methane is metered into downstream nozzle sections in suitable proportions for reacting with spongeiron delivered into the nozzle section of said engine and/or down streamnozzle sections producing said iron carbide and hydrogen whereby saidhydrogen is then recycled into a suitable previous rocket engine reactorto reduce the iron oxide thereby producing a substantial amount ofsponge iron.
 5. The process according to claim 3 for cracking methaneand largely paraffin feed stocks to largely olefin and diolefinmixtures, methane to ethylene/acetylene and ethane to ethylene forexample, whereby a largely steam source is developed in a rocket enginecombustion to discharge a transonic jet to interact with feed stockmetered into the nozzle section of said engine and/or down stream nozzlesections with said jet accordingly cracking to discharge ethylene andsteam for suitable separation.
 6. The process according to claim 5 wherethe downstream reactor comprises at least three optional cracking zonesfor flexibility locating precise shock zones under various flowvelocities and shock related pressure differences for a substantialrange offered by said relatively unlimited stagnation pressure in saidrocket engine combustion.
 7. The process according to claim 5 forproducing ethylene whereby synthesis gas co-produced is the pyrolysisgas in a first stage supply in addition to producing some synthesis gasfor export and/or for the means of said mechanical energy an additionalamount is provided in recycling as a substantial source of fuel for saidrocket engine and/or a prime mover so that by difference of the totalsynthesis gas flow, sufficient synthesis gas is provided for theproduction of ethylene according to the following procedure wherebysynthesis gas at high pressure is delivered in prescribed quantity intothe combustion of a second stage rocket engine and fired therein toproduce a suitable pyrolysis jet for cracking methane and largelyparaffin feed stocks metered into the nozzle section of the rocketengine and/or one or more nozzle sections down stream of the nozzle tosaid last stage rocket engine.
 8. The process according to claim 5whereby said supersonic flows are organized as one or more symmetricalpairs angling into and fairing into and along the main flow produced bysaid engine jet as admixed with a prescribed amount of ethane directedinto said engine nozzle section and/or one or more said nozzle sectionsdown stream.
 9. The process according to claim 5 whereby suitablearrangements are made to at least partially quench the product flow byuse of steam, water or other chemicals.
 10. The process according toclaim 2 or claim 3 whereby said fluid power is applied to expand in oneor more independent free turbines, or gas turbine whereby the exhaustgases from said turbines are directed to commingle with said products ofsaid combustion in compliance with said prescribed temperature and massfor the export power of said turbines.
 11. The process according toclaim 10 whereby the heat and/or mass exceed the requirement of saidturbines, then, the excess is converted thermochemically into fuel forat least powering said compression energy and/or said rocket engine. 12.The process according to claim 3 whereby reactive matter is introducedin said continuum for thermochemical conversion into hydrogen, syntheticfuels, olefins/acetylenes and other chemical products.
 13. A process fora cracking reaction or other chemical reaction, whereby a largely steamsource is developed in a rocket engine combustion to discharge through atransonic nozzle to interact with feed stock metered into the nozzlesection of said engine and/or into one or more down stream nozzlesections whereby said cracking or other chemical reaction is programmedat least at one reactor station between said nozzle sections over arange of flow velocities and steam-to-feed ratios thereby respectivelyresulting in the products of said cracking or other chemical reaction.14. The process according to claim 13 whereby said feedstock isoptionally directed into the high pressure side or low pressure side ofsaid transonic nozzle and/or into the high pressure side or the lowpressure side of said downstream nozzle sections.
 15. The processaccording to claim 13 or claim 14 whereby said reactor stations compriseoptional reaction zones for controlling yield selectivity over wide flowvelocities for various pressures offered by relatively unlimitedstagnation pressure in said rocket engine combustion.
 16. The processaccording to claim 14 whereby said feedstocks entering into said nozzlesections are accelerated to transonic velocities by the parent jet fromsaid rocket engine which is programmable up to Mach 5 and higher. 17.The process according to claim 13 whereby steam is generated in situ bywater being metered into said combustion and/or into an additionalsection just down stream of said nozzle and before said reactor stationwhereby said steam is generated by direct heat transfer from the hot jetemanating from said nozzle at a selected temperature up to 5000° F. 18.The process according to claim 17 whereby power for recycling condensateis provided by expanding the flow after a cracking or other chemicalreaction.
 19. A process for developing a source of compressed hot gasesexpanded in a turbine for export power whereby a substantial portion ofthe exhaust from said turbine is independently compressed and deliveredinto a quasi adiabatic continuum for ultimate delivery of said gas alongwith gases also independently compressed and likewise delivered intosaid continuum which together at the end of said continuum, at leastcomprise a hot flow at a prescribed temperature and pressure for saidexport power.
 20. The process according to claim 19 whereby at least aportion of said compressed gas is first delivered to the combustion of arocket engine at the head of said continuum at a pressure substantiallyhigher then said prescribed pressure so that the difference between saidpressures is substantially converted to useful heat from friction headlosses in the intermingling of said gases between said combustion andthe entry to said turbine.
 21. The process according to claim 19 wherebysaid independent compression is provided by any prime mover and furtherwhereby the exhaust of said prime mover is also recompressed by saidprime mover and delivered into said continuum as a constituent of saidgases.
 22. The process according to claim 19 whereby the flow downstream of said combustion includes unreacted oxygen to support anafter-burning thrust by fuel metered into a junction in said continuumchosen to maximize the thrust of the increased mass flow thereby intosaid turbine.
 23. A rocket engine firing in a continuum to power one ormore expansion turbines whereby a substantial portion or the exhaust isseparated into a minimal stream and a maximal stream to be separatelyrecompressed by preferably a single independent prime mover whereby saidminimal stream is selected in size and compressed for delivery at toppressure into the combustion of said rocket engine and said maximalstream in cooperation with said size is compressed to a substantiallylower pressure than said minimal stream into one or more secondary portsdownstream of the jet developed by said rocket engine so that said jetprovides enough momentum for propelling said maximal stream in mixingwith the constituents of said jet to the design pressure for deliveringsaid power for said expansion turbines.
 24. The process according toclaim 23 whereby additional independently powered jet propulsions areintroduced further down stream in said continuum to boost momentum fromsaid engine.
 25. The process according to claim 23 or 24 whereby theexhaust from said prime mover is also recompressed by same said primemover for delivery into said continuum and/or for delivery as a directand/or indirect heat transfer media to the interstages of said expansionturbines.
 26. The process according to claim 25 whereby said rocketengine and said continuum conform in stream line to replace gas turbinecombustors in retrofit gas turbines.
 27. The process according to claim23 or claim 26 for independently increasing the combustion efficiencywhereby the fuel fired in said engine as a minimal part is selected incooperation with the maximal part of the same fuel whereby said maximalpart is delivered into one or more secondary ports of said engine toadmix and react with the water vapor in said continuum therebytransforming into a fuel gas which fires by auto ignition and/or isignited towards the end of said continuum for entry into said turbines.28. A cycle comprising an expansion turbine means and an independentprime mover for recompressing a substantial portion of the exhaust fromsaid turbine means whereby said portion is admixed with the exhaust fromsaid prime mover which is also recompressed by the same said prime moverand conforming thereafter in a near adiabatic continuum at the designpressure for powering said turbine means and further whereby thedeficiency in mass flow for said cycle is made up by additionally firinga fuel of consistent chemistry with oxidant at said pressure in saidcontinuum to also admix with the compressed products from said primemover in said continuum to expand into said turbine means.
 29. A rocketengine powered steam-complemented jet flow process to selectivelyactivate equilibrium and non-equilibrium chemical reactions whereby flowderives from a fuel gas and whereby its hydrogen component largelyconverts to steam, when fired with a any oxidant in the combustion ofsaid engine, and then said flow proceeds down stream through two or moreinterconnected adiabatic ducts in series to bombard and transfer heat toreact carbonaceous feed stock selectively injected into one or morelocations in said ducts which are selectively interspersed with nozzlesfor provisionally accelerating subsonic flows and decelerating cascadingsubsonically shock-interrupted supersonic flows and further whereby saidducts are contoured to conform to and are interconnected with saidnozzles.
 30. A process whereby high subsonic or supersonic steam orsteam-complemented jet flow is directed to selectively activateequilibrium and non-equilibrium chemical reactions down stream of saidjet through two or more interconnected, adiabatic ducts in serieswherein said flow proceeds to pyrolyze and transfer heat to reactivecarbonaceous feed stock selectively injected into one or more locationsinto said ducts which are interspersed with nozzles for provisionallyaccelerating subsonic flows and deceleratingsubsonically-shock-interrupted supersonic flows and further whereby saidducts and said nozzles are contoured to conform with respect to saidreactions and in addition to comply with the following functions: A. Toset said reactions by causing the reaction temperatures to drop by atleast accelerating the product flow in the last duct. B. To separate theproduct gases by condensing the remaining steam; C. To return saidremaining steam condensate to largely become the source of steam in saidjet thereby substantially closing the cycle of said process.
 31. Aprocess according to claim 30 whereby said steam is generated in aboiler which is the top or first stage source of pressure for said jetflow.
 32. A rocket engine powered process for producing olefins anddiolefins, mainly ethylene and acetylene, whereby steam, applied for thepyrolysis or thermal cracking of a wide range of hydrocarbons includingethane, liquefied petroleum gases, petroleum fractions, petroleum cokeand coal, is sequentially recycled as condensate after separation fromsaid olefins by being pumped into the combustion of said engine wherebysaid condensate becomes steam by direct heat exchange with the productsof combustion in said engine in preparation for and providing saidproducts are compatible with said pyrolysis.
 33. A process according toclaim 32 whereby a fuel rich mixture is fired in the combustion of saidengine in order to provide a propulsive and/or heating function byintroducing oxidant down stream to complete the combustion of saidmixture.
 34. A process according to claim 32 whereby said intermixing isenhanced by transonic flow by providing “bottle shocks” and/or a focusednormal shock in said duct sections.
 35. A process according to claim 32or 33 provided with flows through up to five duct sections, and beforeexpanding in a turbine whereby all the flows throughout take place atvery high subsonic velocities.
 36. A process according to claim 32whereby the boundary layers are dispersed by suitable application ofsteam injection through perforations, slits in the wall of said duct, orthrough duct walls of porous media.
 37. A process according to claim 32whereby the fuel for said engine is hydrogen fired with oxygen wherebysaid hydrogen is provided by a first stage rocket engine power sourceand a separate conserved energy reactor which converts carbonaceousmatter and steam via the water-gas/shift reaction.
 38. An engine processwherein the products of combustion are controlled by suitable means toreach steady state substantially in the form [CO₂+2H₂O]+x[CO₂+2H₂O]whereby the first term relates finally to stoichiometric firing withoxygen while the complementary x term is the diluent which establishesthe operating temperature of said engine.
 39. A process according toclaim 38 hereby said first term [CO₂+2H₂O] products which continuallydischarge from the process are subjected to the condensation of the 2H₂Opart in order to separate the CO₂ part for sequestration by suitablemeans.
 40. The method according to claim 12 whereby a gas turbine isfired with air discharging products of combustion substantially in theform of [CO₂+2H₂O7.53N₂]+Y[CO₂+2H₂O+7.52] is retrofitted to fire withoxygen because of the greater specific heat of its products ofcombustion than with air, and in order thereby to increase the massexpanded in the turbine at its metallurgical upper turbine inlettemperature limit to deliver more power, as well as increasing thethermal efficiency by precluding nitrogen in the exhaust.
 41. A processwhereby a combustion powered jet, discharging from top stagnationtemperature and pressure, cascades into an adiabatic continuum whichreceives branch line flows, likewise adiabatically contained, atcompatible pressures with said continuum whereby the momentum of saidjet interacts with said flows to comprise a composite fluid culminatingtoward the end of said continuum at a prescribed temperature, pressureand mass for expansion power whereby all the energy in said jet combineswith the total energies in said flows to equal the enthalpy [h=u+pv] forexpansion power.
 42. A process according to claim 41 whereby said branchline flows are independently powered and compressed, wherein anyfriction head losses in said line convert to useful heat in said flowswhich is delivered to said composite fluid thereby contributing to saidenthalpy for said power.
 43. The process according to claim 10 wherebysaid exhaust from said turbines is arranged to first transfer asubstantial amount of its heat to said products of said combustion aftersaid compression whereby said exhaust being thereby cooled is thenredirected to commingle with said products ahead of said compression.44. The method according to claim 3 or claim 10 whereby said fuel asapplied to said turbines is not combusted or is only partially combustedso as to exhaust from said turbines with a remaining fuel content to befired in said combustion powered energy and/or in said rocket engine.45. A rocket engine jet powered process for producing olefins anddiolefins, mainly ethylene and acetylene, whereby steam applied forpyrolysis or thermal cracking of a wide range of hydrocarbons includingethane, liquefied petroleum gases, petroleum fractions, petroleum cokeand coal whereby said engine is fired with hydrogen and oxygen therebyproducing the steam requirement for said cracking.